New Cosmos Electric PS-7 User manual

PS-7 Series
Extractive Pump Gas Detector
(Detachable Sensor and Sampling Units)
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options, this manual will be superseded by your delivery specifications.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-018-02
Aug 2020

Unit Dimensions and
Components

on pages 5 to 9
Sensor Unit
Installation/Replacement
9-
on pages 34 to 36
Base Unit installation/Wiring
6-
Operation
7-
Normal operation on page 24
点滅
Troubleshooting 10. Troubleshootingon pages 40 and 41.
点滅
Trouble Alarm
7-Trouble Alarm Operationon
pages 26 and 27
Gas Alarm
7- page 25
Gas inlet
Gas outlet
Cable entry
Flashing
Flashing

Table of Contents
1. Introduction ...................................................................................................................................................1
2. General Precautions.....................................................................................................................................2
3. Package Contents.........................................................................................................................................3
4. Block Diagram...............................................................................................................................................4
5. Unit Dimensions and Components...............................................................................................................5
5-1. Exterior Appearance..................................................................................................................................5
5-2. Main Unit.................................................................................................................................................... 6
5-3. Base Unit...................................................................................................................................................7
5-4. Operation Buttons......................................................................................................................................8
5-5. LCD Indicator Icons...................................................................................................................................9
6. Installation and Wiring.................................................................................................................................10
6-1. Unit Installation Procedure...................................................................................................................... 11
6-2. Tube Fitting Connection Procedure.........................................................................................................12
6-3. Wiring Procedure.....................................................................................................................................14
7. Operation ....................................................................................................................................................15
7-1. Operation Procedure...............................................................................................................................15
7-2. Gas Alarm Operation...............................................................................................................................25
7-3. Trouble Alarm Operation ......................................................................................................................... 26
7-4. Test Mode................................................................................................................................................28
7-5. Maintenance Mode..................................................................................................................................29
8. Maintenance................................................................................................................................................30
9. Consumable Replacement .........................................................................................................................33
9-1. Filter Element Replacement....................................................................................................................33
9-2. Sensor Unit Installation/Replacement.....................................................................................................34
9-3. Sampling Unit Replacement....................................................................................................................37
9-4. Activated Chacoal Filter Installation/Replacement..................................................................................39
10. Troubleshooting.......................................................................................................................................40
11. Specifications ..........................................................................................................................................42
12. Warranty..................................................................................................................................................44
13. Disposal of Product.................................................................................................................................44
13-1. Electrochemical Sensor......................................................................................................................... 45
13-2. Hot-wire Semiconductor Sensor............................................................................................................45
13-3. Galvanic Cell Sensor for Oxygen Detection..........................................................................................45
14. Glossary ..................................................................................................................................................46

-1-
1.Introduction
Thank you for purchasing the New Cosmos PS-7 series extractive pump gas detector. Before using it,
please read this instruction manual carefully to ensure reliable and safe operation.
This unit detects semiconductor process gas or combustible gas (e.g., hydrogen) that may be present in a
cylinder cabinet, an exhaust duct, or an industrial facility work environment (e.g., semiconductor
manufacturing plant) and transmits the gas concentration value as an analog signal to an external device
while simultaneously showing the gas concentration value on its display.
If the gas concentration reaches the preset level, the red ALARM LED will start flashing and activate the
relay contacts, thus monitoring the concentration of the leaked target gas.
Sensor and sampling units can be easily replaced without tools. After the replacement of a sensor/sampling
unit, on-site calibration using a prepared gas is not necessary.
Periodic maintenance is essential to maintain the reliability of the detector. Therefore, perform periodic
maintenance in accordance with the instructions given in this manual.
PS-7 series gas detectors are divided into the following six models according to the sensor unit type and
with/without a pyrolyzer. For sensor selection, please contact New Cosmos or its authorized representative.
Sensor unit type
With
communication function
Without
communication function
(COMM-less model)*
Toxic gas sensor unit
CDS-7
PS-7-01
PS-7-04
Combustible gas sensor unit
CHS-7
Oxygen sensor unit
COS-7
PS-7-02
Toxic gas sensor unit and
pyrolyzer CDS-7+CDP-7
PS-7-03

Toxic gas sensor unit with built-in
pyrolyzer CDS-7
PS-7-05
PS-7-06
* COMM-less models are not equipped with Personal DigitalAssistant (PDA) communication or
DeviceNet communication function, and do not comply with CE marking.
* A DeviceNet unit (sold separately, specified during order placement) is required to use DeviceNet
communication.
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
To ensure safe operation, follow the precautions given below.
Only use this product in accordance with the applicable laws and regulations.
Wiring and installation should only be performed by a qualified electrician with knowledge of
wiring/installation procedures.
DANGER
This product is not explosion-proof and thus should not be installed in a hazardous area.
CAUTION
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 and thus should be kept away from water.
Only use this product in accordance with the applicable laws and regulations.
Set the main unit power switch (located on the front of the base unit) to the OFF position
before installing/removing the main unit. Installation/removal while the main unit power switch
is in the ON position may cause a false alarm or device failure.
WARNING
In the event of a gas leak alarm, follow safety procedures in accordance with your company's
regulations.
Ground the detector to prevent electric shocks.

-3-
3.Package Contents
The following items are included in a standard package. If any items are missing or damaged, please contact
New Cosmos or its authorized representative for replacement.
Standard contents
Item
Quantity
Gas detector (PS-7)
1
Half union (R1/4-ø6mm or R1/4-ø1/4 in. selectable)*1
2
Replacement filter elements (FE-1, 12 pcs.) for MF-50 filter unit
1
Replacement fuse (125 V, 1.0 A), normal blow or time lag*2
1
Mounting screws (M48)
2
Outlet spacer
1
Test stick
2 *3
Instruction manual (this document)
1 *4
PS-ministrators
(Doc. No.GAE-019-xx)
1 *4
Activated charcoal filter outer sleeve (KF-6S-6Z or KF-6S-6ZH)
1 *5
*1.Specified during order placement. R1/4- ø6 mm is shipped for unspecified orders.
*2.Normal blow type fuse is provided for COMM-less model.
*3.Two pcs. are provided per system.
*4.One pc. is provided per system.
*5.One pc. is provided with a PS-7-05 or PS-7-06 unit. An activated charcoal filter
inner sleeve (KF-6S-Y1) is provided with a separately sold sensor unit and not
contents. Fittings will be provided as per the delivery
specifications.
Note 1: Sensor units are sold separately and not included in the standard contents.
Note 2: For the package contents of the models with a DeviceNet unit, refer to the
 instruction manual.
Optional items (sold separately)
Item
Quantity
Filter unit (MF-51)*6
As ordered
Gas collector (PF-D1)
As ordered
Loop checker (LC-7)*7
As ordered
*6.Recommended in the case of monitoring highly adsorptive gas (e.g., HCl, Cl2, NH3)
other than HF and F2.
*7.Only for COMM-less models use.

-4-
4.Block Diagram
Max. load: 125 VAC or 30 VDC 0.5 A (resistive load) for gas alarm contact output (ZA1/ZA2-ZC)
Max. load: 30 VDC 30mA(resistive load) for trouble alarm open collector output (TA-TC)
WARNING
Turn off the gas detector before wiring to prevent electric shocks.
Ground the gas detector to prevent electric shocks.
Ensure correct polarity when connecting the trouble alarm open collector (TA: + / TC: -). Due to
the built-in protection diode, incorrect polarities will cancel an active trouble alarm output.
CAUTION
The analog output line and power line of the gas detector are not isolated from each other.
When using with external devices, provide isolation to prevent noise from other power lines
from interfering with the analog output of the detector.
When wiring, place wires to avoid potential noise sources (e.g., large power transformers,
motors, and powers supply units).
Ensure cables between the gas detector and external devices are connected correctly.
Gas out
Rc 1/4
LCD
Maintennce
SW
P
Pump
Sensor
Flow
sensor
MF-50 filter unit
Gas in
Rc 1/4
Gas in
Rc 1/4
Controller
CPU
board
F1
ZA1
ZA2
ZC
TA
TC
Power
24VDC
TB
1st stage alarm
2nd stage alarm
Common
Trouble alarm
Gas alarm contact output (NO)
PW
Jack
Earth terminal
+
-
+
-
TB
FS
Sampling unit
P
N
G
H
E
SW
1
SW
2
TR
AL
Membrane
SW panel
Analog output
420mADC
Trouble alarm open controller output (NC)

-5-
6
5.Unit Dimensions and Components
5-1. Exterior Appearance
(Dimensions are in mm)
Item
Component
Description/Function
1
Main unit
Includes a display, a pump and a sensor
2
Base unit
Thread cables through the cable entry hole at the bottom of the
base unit
3
Filter unit (MF-50)
Incorporates a filter element (FE-1) that prevents dust from entering
the gas inlet and the sensor
4
Inlet spacer
Prevents the filter unit from being over-tightened
5
Latch (2 places)
Secures the main unit to the base unit
6
White line (2 places)
Indicates that the latch is in the lock position
3
4
5
1
2

-6-
5-2. Main Unit
(Dimensions are in mm)
Item
Component
Description/Function
1
Green POWER LED
When lit, it indicates that the unit is in normal operation
mode (gas-monitoring mode)
2
Amber TROUBLE LED
Flashing indicates the presence of an internal failure
3
Red ALARM LED
Flashing indicates the presence of a gas alarm
4
LCD
Displays alarm notification, numeric gas concentration
value, gas concentration on a bar graph, trouble
status, maintenance/test mode, and flow-rate status
5
Operation buttons (covered)
Include the setting/adjustment buttons and the TEST
switch
6
Front cover
Gently pull out and slide it down to access the
operation buttons
7
Front panel
Incorporates a built-in main board
8
Sampling unit
Incorporates a built-in pump unit
9
Rear cover
Protects a built-in sensor unit
10
Sensor unit
Can be removed/installed by removing the rear cover
1
2
3
4
5
7
6
8
10
9

-7-
5-3. Base Unit
(Dimensions are in mm)
Item
Component
Description/Function
1
Fuse
Internal circuit protection in the event of a current surge
2

Turns the base unit on/off
3
Mounting hole (2 places)
Dia. 5.5 mm
4
Terminal block (2 places)
Used for external wiring
5

Turns the main unit on/off
*If the b is off, no power is supplied
to the main unit
6
MNT switch
(maintenance switch)
Switches between the maintenance mode 1 (MNT1),
maintenance mode 2 (MNT2), and normal operation mode
(center position)
7
Pyrolyzer connector
Supplies power to a connected pyrolyzer (CDP-7)
*Not provided for COMM-less models
8
Gas inlet
Thread size: Rc1/4
Filter unit (MF-50) is attached to this inlet
9
Gas outlet
Thread size: Rc1/4
10
Grommet
Holds signal and power cables
1
2
3
4
5
7
6
8
10
9

-8-
5-4. Operation Buttons
Item
Component
Panel
marking
Description/Function
1
SPAN button
(Span adj. button)
SPAN
Performs span adjustment. For O2sensor unit
(COS-7), 21%vol adjustment will be performed
2
ZERO button
(Zero adj. button)
ZERO
Performs zero adjustment for toxic/combustible
gas sensor unit (CDS-7/CHS-7)
3
AL button
(Alarm setting check button)
AL
Used to check the alarm set values
4
COMM. button
COMM.
Imports data from a currently inserted sensor at
the initial startup, etc.
5
UP and DOWN buttons
UP
DOWN
Used to increase/decrease the parameter value
6
Analog output check
connector
CP
Dedicated connector to check t420 mA
analog output
7
TEST switch (recessed)
TEST
Turns the test mode on/off
8
Button for administrator use
(Administrator use)
9
Communication connector
CN
Used for PDA communication
*Not provided for COMM-less models
1
2
3
4
5
6
7
8
9
Pull and slide down the front
cover to access the operation
buttons and TEST switch.
Opening front cover
Front cover
Slide down
Pull open

-9-
5-5. LCD Indicator Icons
Item
Icon/Display
Description/Function
1
Numeric display
Displays gas concentration and the unit of measurement
(e.g., %LEL, ppb, ppm)
2
FLOW
Lit when the flow rate is low. Linked with item 6
3
ALARM1 ALARM2
Lit when the 1st or 2nd stage gas alarm is on
4
SENS.
Lit when there is a sensor fault (e.g., broken wire) or an
incorrect sensor unit has been inserted
5
CONV.
Lit when a broken pyrolyzer wire is detected
*Not used for COMM-less models
6
Flow-rate icon
Represents the flow rate status of sampled gas
Spinning quickly:The flow rate is normal. FL500
indicated on the sub-display
Spinning slowly: The flow rate is reduced. Possible
 or less
indicated on the sub-display
Stopped: The flow rate is too low. Low flow rate
alarm. or lessindicated on the
sub-display
7
Gas concentration on the
bar graph
One bar represents 5% of the full scale value. The bar
graph value increases from left to right, with the far-right
being the full scale value
8
Sub-display
Displays information related to setting, flow rate, etc., at
the bottom-right corner
(Administrator use)
9
TEST mode
Lit when the unit is in test mode
10
MNT1 / MNT2 mode
Lit when the unit is in maintenance mode 1 or 2
1
2
4
6
9
10
8
3
5
7
LCD

-10-
6.Installation and Wiring
WARNING
For detection of highly adsorptive gas (e.g., HF and F2), remove the filter element (FE-1)
from the filter unit (MF-50). Correct detection is not possible if the filter element is present.
Refer to 9-
Typical gases for which FE-1 should be removed
Gas name
Chemical formula
Hydrogen fluoride*
HF
Tetrafluorosilane
SiF4
Boron trifluoride
BF3
Tungsten Hexafluoride
WF6
Fluorine
F2
*For detection of hydrolyzed HF, the filter element (FE-1) should be removed.
Tubing should be Teflon, dia. 6/4, and less than 20 m in length. For detection of highly
adsorptive gases (e.g., HF, F2, HCl, Cl2, NH3), the tube length should be less than 5 m.
Typical gases for which the tube length should be less than 5 m
Gas name
Formula
Gas name
Formula
Gas name
Formula
Fluorine
F2
Trichlorosilane
SiHCl3
Ammonia
NH3
Hydrogen fluoride*1
HF
Silicon tetrachlorid
SiCl4
Hydrogen sulfide
H2S
Chlorine
Cl2
Chlorine trifluoride
ClF3
Dimethylamine*1
(CH3)2NH
Ozone
O3
Carbon tetrachloride
CCl4
Tetrakis
(dimethylamino)
titanium
Ti[N(CH3)2]4
Bromine
Br2
Hydrogen bromide
HBr
Arsenic trichloride
AsCl3
Hydrogen chloride*1
HCl
Boron trifluoride
BF3
Phosphorus
trichloride
PCl3
Boron trichloride
BCl3
Tungsten Hexafluoride
WF6
Phosphoryl chloride
POCl3
Dichlorosilane
SiH2Cl2
Tetrafluorosilane
SiF4
Sulfur dioxide
SO2
*1. For detection of hydrolyzed HF, F2, HCl, or Cl2/NH3, the tube length should be less than 5 m.
*2. For detection of highly adsorptive gases other than those listed in the table above, the tube length should be
less than 5 m.
DANGER
This product is not explosion-proof and thus should not be installed in a hazardous area.

-11-
6-1. Unit Installation Procedure
1. Determine where to place the base unit (positioning) and
secure the base unit to the wall with the two mounting
screws (M4x8).
2. Run the power and signal cables through the grommet
(located at the bottom of the base) and connect the cable
wires to the corresponding terminals (6-3. Wiring
Procedure).
3. To install the sensor unit at this stage, refer to 9-r
Unit Installation/Replacement
To install the sensor unit at a later stage, skip this step and
move to Step 4.
4. Remove the protective film.
5. Ensure that the m is in the OFF
position.
CAUTION
Install the gas detector in a place free from impact and vibration.
Do not install in the vicinity of equipment that can generate high frequencies or a magnetic
field.
Do not use a gas collector in a confined space (e.g., inside a duct).
Do not install the gas detector in a high temperature (higher than 40ºC) and
condensation-prone area.Avoid sudden temperature changes.
This product is not drip-proof and should be kept away from water.
The pressure differential between the gas inlet/outlet and the outside air pressure
(atmospheric pressure) should be within 1kPa. In addition, the pressure differential between
the gas inlet and the gas outlet should be within 1kPa, with negative pressure applied to the
gas inlet. Using the detector under overpressure will cause an excess flow, which may result
in flow rate error or incorrect measurement.
Install the gas detector vertically with its gas inlet and outlet facing down.
Determine the height for the tip of the sampling tube by considering the specific gravity of the
target gas and install the gas detector where gas is expected to accumulate.
Gas type
Installing height
Gas heavier than air
Maximum of 30 cm above the floor
Gas near the specific gravity as air
75 to 150 cm above the floor
Gas lighter than air
Near the ceiling
For the PS-7-05 or PS-7-06 unit, install the provided activated charcoal filter outer sleeve
(KF-6S-6Z or KF-6S-6ZH) to the gas inlet.
Mounting
screw (M4×8)
Protective film
Latch on each side

-12-
6. To install the main unit, pull forward and hold both the latches of the base unit. Connect the main
unit by sliding it onto the rails of the base unit.
7. Push the latches back into place such that the white lines are visible, indicating that the latches
have been locked.
Rail
Fully push latch (lock position).
White line
Latch
WARNING
Ensure that the latches are in the fully locked position (white lines visible). Normal
detection is not possible if the latches are not fully locked.
The protective film is attached to protect the connectors and internal tubing
of the base unit against possible damage while installing the base unit. Once
the main unit has been installed onto the base unit, it is no longer necessary.
Dispose of the used film in accordance with your companys rule and
procedure.
When installing multiple PS-7 units side by side, keep sufficient space
(recommended: 30 mm or more) between each pair of the units for main unit
installation/removal.
NOTE
(2)Align with the rail and slide
on.
(1) Pull forward and hold the latches at both sides (unlock position)

-13-
6-2. Tube Fitting Connection Procedure
Install the half unions (provided) into the gas inlet and outlet.
Follow the precautions below when the metal tube fittings (not provided) need to be installed into the gas inlet
and outlet:
CAUTION
Over-tightening the filter unit inlet may cause the gas inlet to break. When connecting the half
union to the filter unit inlet, secure the filter unit inlet with one adjustable wrench or spanner,
etc. to prevent the filter unit inlet from rotating and another to install to the half union.
CAUTION
Over-tightening the metal tube fitting may cause the gas outlet to break. To prevent this, install
the outlet spacer (provided) to the gas outlet first and then connect the metal tube fitting over
the spacer. Note: The inlet spacer is pre-installed when shipped.
Use metal tube fittings, Swagelock SS-6MO-1-4RT or equivalent, for both the gas inlet and
outlet.
Wrap sealing tape tautly around the threads of each metal tube fitting to prevent slack
(approx. 2.5 wraps).
Tape size: 13 mm (width) x 100 5mm (length) x 0.1 mm (thickness)
Tighten the metal tube fitting until the spacer lightly touches the gas outlet and the metal tube
fitting. Do not over-tighten the tube fitting or the gas outlet may break.
Metal tube fitting
(Swagelock SS-6MO-1-4RT)
Outlet spacer
Gas outlet
Rotate to install the half
union with adjustable
wrench, etc.
Secure the filter unit inlet
with adjustable
wrench, etc.
Gas inlet

-14-
6-3. Wiring Procedure
Terminal
block
Marking
Polarity
Function
TB1
P
＋
Power input (24 VDC)
N
－
G
＋
Gas concentration output
(420 mADC)
H
－
E
Earth terminal
TB2
ZA1
1st stage gas alarm contact output
(Dry NO contact)
Max. load: 125 VAC or 30 VDC 0. 5 A (resistive load)
ZA2
2nd stage gas alarm contact output
(Dry NO contact)
Max. load: 125 VAC or 30 VDC 0. 5 A (resistive load)
ZC
Common for ZA1 and ZA2
TA
＋
Trouble alarm
(NC open collector)
Max. load: 30 VDC, 30mA resistive load
TC
－
Trouble alarm common
(NO: Normally open; NC: Normally closed)
Terminal layout
○
＋
○
－
○
＋
○
－
○
＋
○
－
CAUTION
The analog output line and power line of the gas detector are not isolated from each other.
When using the detector with external devices, provide isolation to prevent noise from other
power lines from interfering with the analog output of the detector.
When wiring, place wires to avoid potential noise sources (e.g., large power transformers,
motors, and powers supply units).
Ensure cables between the gas detector and external devices are connected correctly.
as alarm contact output is intended to be used with resistive loads only. If used with
inductive loads, back electromotive force will be generated, which may fail the operation of the
device or relay contacts.
WARNING
Turn off the gas detector before wiring to prevent electric shocks.
Ensure correct polarity when connecting the trouble alarm open collector (TA: + / TC: -). Due
to the built-in protection diode, incorrect polarities will cancel an active trouble alarm output.
Ground the detector to prevent electric shocks.



-15-
7.Operation
7-1. Operation Procedure
Operation Flow
The corresponding numbered steps are given for items 112 on the following pages.
Amber TROUBLE LED
flashes.
Change the set values.
6. Incorrect sensor unit is
inserted.
Need to change
No need to change
12. Initial startup is completed.
11. Perform zero adjustment.
11. Is this for
toxic/combustible gas
detection?
8. Check the set
values.
No
Yes
6. Self-test
１
Amber TROUBLE LED is off.
Check the tubing for
looseness.
9.10. Check the
sampling gas for flow
rate and airtightness.
Not normal
Normal
11. Is this for low
oxygen detection?
11. Perform 21vol% adjustment.
No
Yes
2. Turn on the base unit
Base unit startup is
completed.
Initial startup
3. Check the analog
output for base unit
１
Low oxygen detection
Check the power
source.
Check the wiring to the
terminal blocks.
No
Yes
Install the sensor unit.
Install the main unit.
5. Turn on the main unit.
4. Is the sensor unit
installed?
Do you detect toxic
or combustible gas?
3. Adjust the analog
output for base unit
No
Yes
Is the main unit off?
Yes
Turn off the main unit.
No
1. Is power voltage
24 VDC±10%?

-16-
Operate the gas detector by using the following steps:
1. Ensure that the power voltage (between P and N on the terminal block) is 24 VDC 10%.
2. Set the b to the ON position.
3. Adjust the analog output for maintenance mode 2 (MNT2).
The MNT2 analog output varies with the sensor unit type. Therefore, the output needs to be adjusted by
using the following steps. Refer to 7-Maintenance Modemation on the maintenance mode.
For COMM-less models, a dedicated loop checker (LC-7) needs to be connected to the base unit for
adjustment. Refer to (2) for details.
(1) Lift the cover flap open. Set the MNT switch to the MNT2 position.
WARNING
When using the 24 VDC power supply, ensure that the power is 24 VDC 10%.
Check that the target gas type and full scale value are correct before using a new sensor unit.
Also, check that the sensor unit expiration date has not been reached.

CAUTION
Before turning on the gas detector, check that all wiring is correct. Refer to 6-3. Wiring
-user-specific options.
Base unit power switch
To MNT2 position
MNT switch
Lift the cover flap open
Power on

-17-
MNT2 POWER LED
Insert
Loop checker (LC-7)
17.4mA/4.0mA switch
(2) For COMM-less models
a. Connect the loop checker (LC-7) to the base unit.
b. Set the MNT2 analog output level to 4.0 mA or 17.4 mA depending on the sensor unit type
using the 17.4 mA/4.0mA switch.
Sensor unit type
MNT2 analog level
CDS-7
4.0 mA
CHS-7
COS-7 (FS: 25vol%)
17.4 mA
COS-7 (FS: 50vol%)
c. Set the m to the ON position.
d. Set the MNT switch to the center position for normal operation mode.
Main unitpower switch
To ON position
Lift the cover flap open
COMM-less models
Lift the cover flap open
To center position (normal operation mode)