New Cosmos Electric PE-2CC User manual

SUCTION TYPE GAS DETECTOR
PE-2CC
PE-2DC
Instruction Manual
 Keep this manual for easy reference.
 Carefully read this manual prior to use.
 This manual describes the standard model. If your unit has end-user-specific
options, this manual will be superseded by your delivery specifications.
Instruction Manual No.
GAE-122-01
March 2023

Table of Contents
1. Introduction .............................................................................................................................. 1
2. General Precautions ................................................................................................................ 2
3. Package Contents ................................................................................................................... 3
4. Unit Dimensions and Components .......................................................................................... 4
5. Installation ............................................................................................................................... 5
6. Wiring .................................................................................................................................... 8
6-1. Wiring Connection ............................................................................................................ 8
6-2. Wiring and Connection ................................................................................................... 1 1
7. Before Use ............................................................................................................................ 13
7-1. Precautions during Use .................................................................................................. 13
7-2. When an alarm is activated ............................................................................................ 13
8. Maintenance .......................................................................................................................... 14
8-1. Routine Check ................................................................................................................ 14
8-2. Annual Inspection ........................................................................................................... 15
8-3. Calibration Gas Preparation ........................................................................................... 15
8-4. Gas Sensor Replacement .............................................................................................. 17
8-5. Filter Replacement ......................................................................................................... 19
8-6. Manifold Plate Cleaning ................................................................................................. 19
9. Specifications ........................................................................................................................ 21
10. Warranty ................................................................................................................................ 21
11. Detection Principles ............................................................................................................... 22
11-1. Catalytic Combustion Sensor ....................................................................................... 22
11-2. Hot Wire Semiconductor Sensor .................................................................................. 22
11-3. Thermal Conductivity Sensor ........................................................................................ 23
12. Glossary ................................................................................................................................ 24

1
1. Introduction
Thank you for purchasing the New Cosmos PE-2CC/PE-2DC suction type gas detector.
To ensure reliable operation, please read this instruction manual prior to use.
The difference between PE-2CC and PE-2DC is the power source for the pump. The
PE-2CC requires 100 VAC, while the PE-2DC requires 24 VDC for the pump’s power
source.
This gas detector can detect one of a variety of gases including combustible gases by
installing one of the three sensor types, catalytic combustion sensor, hot wire
semiconductor sensor, and thermal conductivity sensor.
Prior to use, please read the indicator unit’s instruction manual. This unit is paired with an
indicator unit (e.g., V2, V3), and these pairs can be used in conjunction with one alarm unit
(e.g., VAL, VAS) to form a gas alarm system (e.g., UV-810). Install the gas detector at a
location where detection of the target gas is necessary, and install the indicator unit at a
location that is convenient for monitoring gas concentrations. The indicator unit displays the
gas concentration detected by the corresponding gas detector on its bar graph display. In a
paired setup, the indicator unit produces a visual alarm when the gas detector detects a
concentration of the target gas that is higher than the preset limit. In a gas alarm system
setup, the alarm unit produces audio-visual alarms, if the gas detector detects a leak of the
target gas that is higher than the preset limit.
Symbols Used in this Instruction Manual
This manual uses Danger, Warning, Caution and Note symbols to draw attention to
procedures, materials, methods, and processes, which require particular attention.
DANGER Indicates an imminently hazardous situation that can result in
death or serious injury.
WARNING Indicates a potentially hazardous situation that may result in death
or serious injury.
CAUTION Indicates a hazardous situation that may result in minor injury or
property damage.
NOTE
Provides information on product handling.

2
2. General Precautions
Carefully read this manual prior to use.
Follow the precautions below to ensure safe operation.
Only wire/install/use this product in accordance with applicable laws and regulations.
Only a qualified electrician with knowledge of wiring and installation procedures should
perform wiring and installation.
For explosion-proof wiring and installation, only a qualified electrician with knowledge of
explosion-proof components/installation procedures should perform wiring and installation.
 Ground the product to prevent electric shocks.
 To prevent electric shocks, turn off the indicator unit or gas alarm system, or remove
the power supply during wiring/installation/removal of the gas detector.
 To prevent lightning strikes, countermeasures against lightning should be taken on
the power lines and cables installed outdoors.
 Do not disassemble, modify, or alter the structure of this unit or its electrical circuits.
Doing so may compromise the performance of the product.
 This product is not drip-proof equipment, and should be kept away from splashing
water.
WARNING
CAUTION

3
3. Package Contents
This product is packed and shipped with the utmost care. If any items are missing or
damaged, please contact New Cosmos or its distributor for replacement.
Item Qty.
Gas detector (PE-2CC or PE-2DC) Per your order
Instruction manual (this document) 1 per order
Filter unit (FC-32), with included flow meter 1 per detector
Collecting cone (pipe flare) (PF-N3) *1 1 per detector
Hex wrench set (M2, M4, M5, and M8) 1 per order
Hex screw (M6×25) with nut and washer 4 per detector
Crimping terminal (V-1.25-F3, red color) 6 per detector
*1. The collecting cone is used by connecting it to the end of sampling pipe for water
deflection purposes while raining or sprinkling, and should not be used for sampling
gas in an enclosed area (e.g., inside duct, furnace, or device enclosure).
Optional items
Item Qty.
Protective cover (PW-51) *2 Per your order
Auto drain (AD-40) *3 Per your order
*2. Used on an outdoor installation.
*3. Auto drain is to automatically drain condensation formed while sampling gas at the
furnace or piping pit.

4
4. Unit Dimensions and Components
Figure 1. Outer Appearance
Item Component Qty. Description
1 Case 1
2 Terminal case 1
3 Manifold plate 2
4 Half joint 2 PT1/8(Rc1/8) ⌀6
5 Mounting bracket 2
6 Gas sensor 1
7 Suction pump 1
8 Terminal block 2
9 Hex screw (M10) 8
10 Name plate 1
Ground terminal
④
Ground terminal

5
5. Installation
 Joint surfaces are important members for ensuring the explosion-proof performance
of the product. Do not damage or strike joint surfaces during installation. Keep joint
surfaces clean and free from any damage. Contaminates such as scratches,
fingerprints, dirt and oil may adversely affect the explosion-proof characteristics of
the product.
 The pipe material (dia. 6/4) connected to the detector, should be suitable for the
target gas. The pipe length should be 30m or less.
 Do not install the gas detector in the following conditions
- Ambient temperature is outside the specified operating temperature range
of -10C to +40C (-10C to +70C if your unit has the heat-proof option).
- Condensation prone areas
- Exposure to water spray
- Presence of corrosive gas
- Exposure to sunlight
- Sudden temperature changes
- In the vicinity of equipment which can generate high frequencies or a magnetic
field
 Install the gas detector in a place free from vapor containing silicon compounds. Not
doing so may compromise the gas sensor’s performance.
 Install the gas detector in a place free from vibration.
 Avoid impacts to the gas detector.
 Use a protective cover (PW-51, sold separately) for outdoor installation.
 Use an auto drain (AD-40, sold separately) when installing the suction type gas
detector in a place where it may draw water, e.g., near a vapor outlet.
 The detector should be installed in accordance with applicable laws and regulations.
Refer the table below (Installation Height table) to determine the installation height of
the sampling port based on the specific gravity of the target gas. Install the gas
detector in a place where the target gas is likely to accumulate and the detector can
be easily accessed for maintenance or inspection.
 The atmospheric pressure in a gas sampling location should be 1kPa. If 1kPa is
exceeded, consult with New Cosmos or its authorized representative.
 When exhausting the emission by connecting the gas detector’s exhaust outlet to a
duct etc., the back-pressure should be 1kPa or less.
CAUTION

6
Installation Height
Install the detector’s gas sampling port in the following places which are not easily
accessed for maintenance or inspection, while the gas detector itself should be
installed in a place that is easily accessible.
(1) Inside a piping pit or at an enclosed place
(2) in a furnace
(3) At high or low temperature
(4) At an elevated location
Connecting the Sampling Pipe to Gas Detector
Use pipes (dia. 6/4) suitable for the gas to be detected. Connect the pipe to the gas
detector with a half joint (2 locations, gas in and out). Two joints with sleeve and nut for
copper piping (dia.6/4) are pre-installed when shipped.
Figure 2. Pipe Connection with Half Joint
Gas type Installing height Remarks
Gas heavier than air
(e.g., LPG)
Maximum of 10cm above
the floor
Determine the height by
considering easy
maintenance and
inspection.
Gas near the specific
gravity as air
(e.g., Carbon monoxide)
75 to 150 cm above
the floor
Determine the height by
considering the specific
gravity of the target gas
and mounting
environment.
Gas lighter than air
(e.g., Natural gas and
hydrogen)
Near the ceiling Determine the height by
considering layout (e.g.,
scaffold) for easy
maintenance.

7
Figure 3. In Piping Pit Figure 4. At Elevated Location
Install the collecting cone above any water so that it will not be drawn in.
Protective Cover and Auto Drain Installation
Figure 5. Protective Cover Figure 6. Auto Drain
Secure the protective cover in the event of forecasted high winds, storm, or a
typhoon. E.g. tether, string, or lash.
CAUTION
CAUTION

8
6. Wiring
Please refer to the indicator unit’s instruction manual along with this manual.
6-1. Wiring Connection
Perform explosion-proof enclosure wiring when installing the gas detector in a hazardous
area.
(1) Wiring up to this product (here explained in case of using rigid steel conduits
method)
 Only perform wiring and installation of this product in accordance with applicable
laws and regulations.
 Only a qualified electrician with knowledge of components/installation procedures
should perform wiring and installation.
 For explosion-proof wiring and installation, only a qualified electrician with
knowledge of explosion-proof components/installation procedures should perform
wiring and installation.
 Only use separate insulated wires when using the explosion-proof rigid steel conduit
method (do not use a bundled cable).
 Use the appropriate rubber, vinyl, or polyethylene insulated wires based on the
ambient humidity and temperature.
 Sheath all wires used in rigid steel conduits (JIS C 8305). To prevent the formation of
a flame path for explosive gas or fire inside the conduits, use conduit sealing fittings
filled with compounds.
 Do not use silicon type compounds for sealing the conduits. Doing so may
compromise the performance of the gas sensor.
 When flexibility is required, use explosion and water proof flexible conduits. Rain or
other liquid entry inside the gas detector may cause a function loss or malfunction of
the detector.
 Waterproof joints between conduits, fittings and joint boxes. Rain or other liquid
entry inside the gas detector may cause a function loss or malfunction of the
detector.
CAUTION

9
Use parallel pipe threads (JIS B 0202) for connections between conduits,
fittings, and joint boxes. This gas detector comes with PF3/4 female threads
(G3/4). Engage at least five threads per connection, and then firmly tighten
with a lock nut.
Figure 7. Typical Layout
(2) Wiring connection to this product
There are two wiring connection methods, rigid steel conduit method and pressure-resistant
gasket type cable gland method. Below is the pressure-resistant gasket type cable gland
method.
 Use a rubber, plastic or metal sheathed cable appropriate to the installation environment.
The cable should have a circular cross section and its outer surface should be smooth
and even. For protection, the cable may be sheathed in a protective casing, such as a
metal conduit or carbon steel pipe. Other protective structures such as metal or concrete
ducts are also acceptable.
 Connecting a cable to another cable outside the gas detector is not recommended. Direct
or branching connections of cables should be done inside the gas detector or
explosion-proof terminal box.

10
 Use cable whose outer diameter matches the inner diameter of the gasket by referring to
the table below. Fully tighten the cable gland, to prevent the formation of a flame path for
explosive gas or fire.
Figure 8. Gas Detector Connections
Cable outer dia. Gasket inner dia. Washer inner dia.
12 -12.9 13 14
13 -13.9 14 14
14 -14.9 15 15

11
6-2. Wiring and Connection
(1) When connecting the power line,
Use a dedicated breaker for the power line going to the indicator unit which is connected to
the gas detector.
(2) When connecting power and signal lines between the gas detector and indicator unit,
Use a cable, such as a 600V vinyl insulated (IV), VCT or CVV cable (with 0.75mm2 to
2.0mm2 wires).
Ensure that the load resistance of the signal line, including the resistance of
the wire, is 10 ohm or less. Refer to below for cable length.
0.75 mm2 cable: 400m or less
1.25 mm2 cable: 600m or less
2.00 mm2 cable: 1km or less
 Before opening any part of the gas detector, turn off the indicator unit connected to
the gas detector to eliminate possible source ignition.
 Ground the gas detector to prevent electrical shocks.
 Refer to the terminal markings to ensure that the wires are correctly connected
between an indicator unit and a gas detector.
 Keep the connection cable (power/signal lines to gas detectors/alarm unit/indicator
units) away from other power lines.
 Only perform wiring and installation of this product in accordance with applicable
laws and regulations. Refer to 6-1. “Wiring Connection”.
 When connecting the pump power lines to the PE-2DC unit, ensure that the polarity
is correct. Connect so that the PA and PB terminals should be respectively positive
and negative.
 The required power supply for the pump is different between PE-2CC and PE-2DC.
100VAC is required by PE-2CC and 24VDC by PE-2DC. Wire the correct source.
Remove the sticker from the pump power terminals of the indicator unit, then
connect the gas detector’s pump power lines to them.
WARNING
CAUTION

12
Indicator Unit Terminal Block Gas Detector Terminal Block
R Pump Power
Supply AC100V
S
A
Gas Detector
B
C
D
Figure 9. PE-2CC Wiring Diagram
Indicator Unit Terminal Block Gas Detector Terminal Block
PA (+) Pump Power
Supply 24VDC
PB (-)
A
Gas Detector
B
C
D
Figure 10. PE-2DC Wiring Diagram

13
7. Before Use
Before turning on the unit, check that all the components are connected correctly.
The markings on the indicator unit and gas detector must match.
7-1. Precautions during Use
Do not place your face closer to the exhaust port of the gas detector. Deoxygenated
air or gas harmful to humans may be inhaled.
7-2. When an alarm is activated
Remain calm and check that there is no fire present. Do not touch any electric
switches under any conditions. Sparks caused by turning on or off electric switches
may cause an ignition.
If there is a gas leak alarm, take the necessary measures specified by your
company.
CAUTION
DANGER
DANGER
CAUTION

14
8. Maintenance
Routine checks are carried out by the user, while annual inspections are performed by New
Cosmos or its authorized representative.
8-1. Routine Check
(1) Visual check (min. one per month)
 Check the gas detector for corrosion.
 Check the mounting brackets, screws, fittings, piping, etc. for corrosion.
Visually check and replace any worn or damaged parts.
(2) Flow rate check (min. one per month)
Measure the flow rate with the filter unit (FC-32).
A flow rate greater than 0.7 l/min, indicates a normal flow rate.
If the flow rate is lower, the probable cause is clogging at the following locations. Visually
check the locations below for clogging and clean or replace the parts as needed.
 Sampling port (collecting cone)
 Sampling pipe
 Manifold plate
 Filter
If the flow rate does not change after filter replacement, check the sampling port, pipe,
and manifold plate for problems. Replace the suction pump with a new one if needed.
(3) Alarm test by using an actual gas (min. every 2 or 3 months)
Remove the cap from the filter unit (FC-32). Connect
a gas bag (which contains calibration gas) to the inlet
port of the filter unit. Apply the calibration gas into the
inlet port and check the operation of the alarm. Refer
to Figure 11.
For the method on how to prepare the calibration gas,
refer to 8-3. “Calibration Gas Preparation”.
(4) Check gas detector surroundings
Ensure that there is no obstacle around the sampling
port which may prevent gas detection. Figure 11. Alarm Test

15
8-2. Annual Inspection (min. one per year)
Important Notice for Annual Inspection
In order to ensure the reliability of the gas detection and alarm system, it is vital to
perform periodic maintenance and inspections. Further, it is necessary to perform
inspections and calibrations by using actual gas (combustible or poisonous gas). It is
highly recommended that a maintenance contract with a local New Cosmos
representative be made for the performance of annual inspections.
Installation, inspection, maintenance, calibration and proof testing shall only be
performed by trained personnel.
Please contact your local representative for more information.
8-3. Calibration Gas Preparation
Prepare calibration gas (2X higher than the alarm set concentration) for use in an alarm test
given in 8-1. (3) “Alarm test by using actual gas” on the previous page.
Typical method to prepare calibration gas, 0.9 vol% (50%LEL) isobutane, is given below as
an example.
Target gas: Isobutene
100%LEL = 1.8vol%
Alarm set value: 0.45vol% (25%LEL)
Calibration gas: 0.9 vol% (50%LEL)
(A) When a commercially prepared gas cylinder is available,
Completely remove air from a gasbag. If residual air
remains inside the bag before filling, incorrect
measurements will result. Connect the gasbag to
the cylinder. Fill the prepared gas into the gasbag as
shown in Figure 12.
Figure 12. Gas Cylinder
Use a urethane gasbag. Leave the gas inside the bag for approx. 30 minutes
before use, to allow the humidity of the gas inside to approximate to the
ambient humidity.
Commercially prepared gas cylinder 0.90 vol% air balance
Gasbag

16
(B) When a commercially prepared gas cylinder is not available,
Use a gas calibration kit (not included) and a pure gas cylinder (isobutane at 99vol% or
more). Dilute pure isobutane with air to produce 0.9vol% (50%LEL) calibration gas.
Ensure that there is no open flame or source of ignition when handling a flammable
gas with the concentration exceeding the LEL.
(1) Completely remove air from a gasbag. Connect the gasbag to a
pure gas filled cylinder. Draw a little more than needed amount of
gas from the cylinder into the gasbag. Bend the tube of the bag
and pinch it using a pinchcock to ensure a leak-proof seal.
(2) Connect a 10ml syringe to the gasbag. Collect 9.0ml of pure gas
into the syringe. (You can collect a little more than needed, then
discharge the excess to obtain 9.0ml.)
(3) Connect the syringe to the inlet port of a measuring pump. Pull
the plunger of the pump drawing the gas into the pump. Remove
the syringe from the inlet port. Pull the plunger of the pump to the
limit (100ml).
(4) Connect an empty gasbag to the outlet port of the pump. Push
the plunger of the pump. Cycle the plunger of the pump nine
times to inflate the bag with the diluted gas.
For example, collect 9.0ml of pure isobutane gas in the pump,
connect the pump to a completely empty gasbag, then cycle the
plunger 10 times. (100ml per push), yielding a 0.9 vol% gas or
50%LEL gas:
9.0ml / (100ml×10) =0.0090 (0.9vol % diluted gas).
The LEL of isobutane is 1.8vol%.
0.9/1.8×100=50 (50%LEL diluted gas)
Figure 13. Gas Preparation
DANGER
(1)
(2)
(3)
(4)
Pure gas cylinder
Keep it upright.
Pure gas (9.0ml)
Measuring pump
Pure gas in gasbag
Diluted gas
in gasbag
Pull syringe plunger

17
8-4. Gas Sensor Replacement
Before opening any part of the gas detector, turn off the indicator unit connected to the
gas detector to eliminate possible source ignition.
Joint surfaces are important members for ensuring the explosion-proof performance of
the product. Do not damage or strike joint surfaces during replacement. Keep joint
surfaces clean and free from any damage. Contaminates such as scratches,
fingerprints, dirt and oil may adversely affect the explosion-proof characteristics of the
product.
(1) Remove the four hex screws (M10) from the electronics case with a hex wrench, and
remove the cover from the case.
(2) Remove the four terminal screws (M3×8) and washers to free the crimping terminals
from the terminals (1 to 4).
(3) Remove the four screws (M3×15) and washers attaching the printed circuit board to the
electronics case. Remove the printed circuit board and sensor retainer.
(4) Pull to remove the gas sensor. Place the ring gasket (P26) in the sensor holder, then
place a new gas sensor on the ring gasket. A “●” mark is printed on each gas sensor.
Install the new sensor so that its “●” mark faces toward the gas inlet (facing diagonally
up and left when viewed from the front).
(5) Feed the sensor’s lead wires through the hole of the sensor retainer and printed circuit
board.
Place the sensor retainer and printed circuit board on the top of the sensor holder, then
tighten the four screws (M3×15) and washers.
Install the sensor retainer in a correct orientation.
(6) Match the colors of the lead wires from the sensor and the lead wires from the gas
detector by referring to the table below. Color combination defers depending on the
sensor type.
Tighten the terminal screws (M3x8) to secure the lead wires.
(7) Install the top cover in the electronics case and tighten the four hex screws (M10).
Return used gas sensors to New Cosmos Electric.
WARNING
CAUTION

18
Catalytic combustion sensor
Lead wire from sensor Terminal Lead wire from terminal case
Pink 1 Red
Black 2 Black
White 3 White
4 Green
Hot wire semiconductor sensor
Lead wire from sensor Terminal Lead wire from terminal case
Orange 1 Red
Black 2 Black
White 3 White
4 Green
Thermal Conductivity sensor
Lead wire from sensor Terminal Lead wire from terminal case
Brown 1 Red
Black 2 Black
White 3 White
4 Green
Figure 14. Gas Sensor Replacement