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New Cosmos Electric PS-7 Operation Manual

Extractive gas detector
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EXTRACTIVE GAS DETECTOR
O P E R A T I O N M A N U A L
Model PS-7
Contains the PS-7, PS-7 Administrator & Pyrolyzer Manuals
• Store this operation manual in a convenient location, and consult it whenever necessary.
• Operate this unit only after reading and fully understanding the content of this manual.
• This manual uses standard specifications. If your specifications are different, the operation manual
that came with your unit takes priority.
740 McArdle Drive, Unit C – Crystal Lake, IL 60014
815-788-5200 Phone
815-788-5300 Fax
www.dodtec.com

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  • Page 1 O P E R A T I O N M A N U A L Model PS-7 Contains the PS-7, PS-7 Administrator & Pyrolyzer Manuals • Store this operation manual in a convenient location, and consult it whenever necessary. • Operate this unit only after reading and fully understanding the content of this manual.
  • Page 2 The name and function of each component How to install the sensor unit →P 5 →P 31 Installation and wiring the base unit When the gas alarm is activated →P 9 →P 23 and P 22 Blinking ALARM2 Cable entry Basic operating instructions The different types of trouble warnings →P 12...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1 Introduction..............................1 2 Safety Instructions ............................2 3 Contents of This Package ..........................3 4 System Flow Diagram ............................ 4 5 Description ..............................5 5-1 Components on the Main Unit ......................... 5 5-2 Details of the Key Switch Section ......................7 5-3 Details of the LCD Screen Display......................

  • Page 4: Introduction

    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.

  • Page 5: Safety Instructions

    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 •...

  • Page 6: Contents Of This Package

    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. Description Quantity PS-7 Gas Detector Male connector (R1/4- ø6) Filter elements (FE-1, 12 pcs.) (For MF-50 Filter Unit) Fuse (0.5 A)

  • Page 7: System Flow Diagram

    4 System Flow Diagram MF-50 (Dust filter) Sampling Unit Sensor Pump GAS OUT GAS IN Rc 1/4 Rc 1/4 Flow sensor GAS IN Controller Rc 1/4 Power DC 24V CPU Board Analog Output 4 to 20 mA DC (4-conductor shielded cable) Maintenance switch Jack...

  • Page 8: Description

    5 Description 5-1 Components on the Main Unit Description Function (Green) Power lamp. Illuminates during regular monitoring POWER lamp operations. TROUBLE lamp (Yellow) The lamp blinks when trouble occurs. (Red) The lamp blinks when the concentration level of detected ALARM lamp gas exceeds that of the preset alarm level.
  • Page 9 ○ ○ ○ Figure 3 Dimension & description (Units: mm) Description Function Fuse 125 V, 0.5 A Base unit power switch The power switch for the base unit. Mounting holes Screw holes (∅5.5) for wall mounting. Terminal strip Used to connect external wiring. Main unit power switch The power switch for the main unit.

  • Page 10: Details Of The Key Switch Section

    5-2 Details of the Key Switch Section 1 Pull back 2 Push down Figure 4 Names and functions of key switches Description Display Function Span adjustment To carry out 21vol% adjustments. SPAN switch (For the COS-7 oxygen sensor unit.) To carry out zeroing. Zeroing switch ZERO (For the CHS-7 flammable gas sensor unit or CDS-7 toxic gas...

  • Page 11: Details Of The Lcd Screen Display

    5-3 Details of the LCD Screen Display LCD display Figure 5 Parts of the LCD screen display Meaning Shows the detected gas concentration (with units). Lights when the flow rate is decreasing. (Also see no. 6 below.) These light when the detected gas concentration exceeds that of the preset alarm level. Lights on when there is sensor trouble, or when a sensor is inserted incorrectly.

  • Page 12: Installation And Wiring

    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 such as HF and F , install the Gas Detector with the filter element (FE-1) removed from the filter unit (MF-50). (Refer to 9-1 Replacing the Filter Element.) •...

  • Page 13: Installing The Main Unit

    6-1 Installing the Main Unit Determine the installation point and attach the base unit using two M4 × 8 screws. M4×8 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.) To attach the sensor unit, refer to 9-2 Attach/Replacing the Sensor Unit.

  • Page 14: Wiring Instructions

    6-2 Wiring Instructions Terminal Sign Polarity Function Board Power supply (24 V DC) − Gas concentration output (4-20 mA DC) − Ground Gas alarm contact output (1 level) (no voltage contact 1a) Rated load: 125 V AC or 30 V DC, 0.5-A resistance load Gas alarm contact output (2 level)

  • Page 15: Operation

    7 Operation 7-1 Operation Procedures Carry out operations in the following manner. Refer to the items inside each box for more detailed instructions Example (listed from the next page) (1)Check power Refer (1) on voltage page 13 24 V DC ±10% Initial setup Outside the range of 24V±10%...
  • Page 16 7-1 Operation Procedures (Contd.) 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. Caution •...
  • Page 17 (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 Instructions.
  • Page 18 For toxic gas sensor unit: CDS-7, or Oxygen sensor unit : COS-7 combustible gas sensor unit : CHS-7 (When full scale value is 50vol%) Analog Oxygen Analog output concentration output concentration Full scale Set analog output to 10.7mA as the regular oxygen concentration is Oxygen sensor unit...
  • Page 19 (6) Begin self-diagnosis after the front lamp and the LCD screen have been on for over one second. When using the main detector for the first time, or when a new sensor unit with different settings (sensor units for which the target gases and full scale values, etc., are different) has been attached: The TROUBLE lamp (Yellow) will blink.
  • Page 20 (8) Check the various setting values The values of the various settings can be checked by pressing the up/ down switch, “ ” or “ ” on the main unit. The setting values are displayed in the bottom right hand corner of the LCD screen. They may sometimes difficult to distinguish due to the types of alphabet letters used.
  • Page 21 Refer to the separate PS-7 Operation Instructions for Administrators to change the values of various settings. - 18 -...
  • Page 22 (9) Verifying the sampling flow rate (Check flow rate) Check to see that the flow rotation rate is high, and the TROUBLE lamp (yellow) is off. If the flow rotation is high, then it is flowing at the designated rate (0.5 L/min). TROUBLE lamp (yellow) Off Rotates quickly Note...
  • Page 23 (11) Adjusting the Zero/21 vol% setting (Zeroing for the CDS-7, CHS-7, and 21vol% adjustment for the COS-7) After power is applied to the main unit, and the appropriate time period has passed (depending on the type of sensor unit), press the appropriate key switch from the below table. Then, be sure to do a readjustment to increase precision.
  • Page 24 For the: For the: Oxygen sensor unit: COS-7 : CDS-7 Toxic gas sensor unit : CHS-7 Combustible gas sensor unit 2. Hold down the ZERO Key for over a second. 2. Hold down the SPAN Key for over a second. It is complete when the POWER lamp It is complete when the POWER lamp (green) blinks once.
  • Page 25 (12) Affix the seal showing target gases to be detected in a clearly visible place on the front of the main body. −Normal operation state− POWER lamp (Green): TROUBLE lamp (Yellow): Off ALARM lamp (Red): Detected gas concentration Flow rate: High rotation Seal showing target gases to be detected Figure 7 Normal operation state...

  • Page 26: Gas Alarm Operating Instructions

    7-2 Gas Alarm Operating Instructions When the concentration level of detected gas exceeds that of the preset alarm level, the alarm contacts are activated after a set time delay, the ALARM lamp (red) blinks, and ALARM1 or ALARM2 is displayed on the LCD screen.
  • Page 27 Note The relationship between 1 level and 2 level alarm values of each alarm mode is as follows: H – H mode (1 level: Upper limit, 2 level: Upper limit) Full Scale level gas alarm : ALARM 1 , ALARM 2 is displayed. Alarm contacts ZA1 and ZA2 are activated Alarm value is set by entering A2 ** level gas alarm : ALARM 1 is displayed.

  • Page 28: Trouble Alarm Operating Instructions

    7-3 Trouble Alarm Operating Instructions The trouble alarm will be activated in the following situations. (The open collector will be ON in normal mode, and OFF during trouble or when the power is disconnected.) The TROUBLE lamp (yellow) will blink, and analog output will drop to below 0.6 mA.

  • Page 29: Test Mode Settings And Operating Instructions

    7-4 Test Mode Settings and Operating Instructions (1) Settings Press the “TEST” key switch on the front of the main unit. When this is pressed once, it will go into test mode. When it is pressed again, it will return to normal mode. *Test mode will automatically be released after 10 minutes.

  • Page 30: Maintenance Mode Settings And Operating Instructions

    7-5 Maintenance Mode Settings and Operating Instructions (1) Settings There are two types of maintenance modes. (See the table below for the functions of each.) Set the maintenance switch at the bottom of the front of the main unit to 1 (left), or 2 (right). Either MNT1 or MNT2 will be displayed on the LCD screen.

  • Page 31: Maintenance And Inspection

    8 Maintenance and Inspection • The Gas Detector unit does not normally require gas calibration to be performed on site. Gas calibration is performed by New Cosmos, so the user is only required to replace the sensor unit every six months. (This does not apply to the CHS-7 Combustible Gas Sensor Unit.) •...
  • Page 32 (2) Sampling flow rate inspection（Flow rate inspection） Check that the flow rate on the LCD screen is rotating quickly. (Refer to 7-1 Operation Procedures (9)). If the flow rate is rotating slowly or has stopped, check the filter element, and replace if clogged or dirty. (See 9-1 Replacing the Filter Element.) If it still is not right after replacing the filter element, check to make sure the pipes are not clogged, or the load is not too high, etc.

  • Page 33: Replacing Consumables

    9 Replacing Consumables • The Gas Detector is designed to allow users to replace consumables. • Contact your local dealer to purchase consumables, or if further instruction is needed regarding their installation and replacement. 9-1 Replacing the Filter Element (FE-1) Use the following procedure to replace the filter element if it becomes dirty or clogged.

  • Page 34: Attach/Replacing The Sensor Unit

    9-2 Attach/Replacing the Sensor Unit Warning Verify that the detected gas type and the full-scale value of the new sensor unit are the same as the sensor unit being replaced. Be sure to check that its expiration date has not passed. (There is no expiration date displayed for the Combustible Gas Sensor Unit CHS-7.) Caution •...
  • Page 35 3. Press back while pushing on the middle of the upper section of the main body cover with your thumb, and remove the cover. Remove by turning. The axis is here (fulcrum). 4. Insert a finger in the gap between the main body and the top of sensor unit, and pull back slightly. Then grasp the sides of the sensor unit, and pull out.
  • Page 36 6. 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. 2. Insert so that it slides along the rails. Rails 1.

  • Page 37: Replacing The Sampling Unit

    9-3 Replacing the Sampling Unit Caution Always turn OFF the power supply before attempting to replace the sampling unit. However, if the power switch to the main unit is turned off to replace the sampling unit, the trouble alarm output (open collector) will also turn off. If alarm contacts are used for interlocking with external devices, verify that the interlock be released prior to replacing the unit.
  • Page 38 4. Connect the 2 front panel connectors to the new sampling unit, and reattach the front panel. After inserting the sensor unit, reattach the main body cover. The axis is here (fulcrum) Front panel Main body cover The axis is here (fulcrum).

  • Page 39: Troubleshooting

    10 Troubleshooting • If a problem occurs, check the following before contacting a service or sales representative. Problem Cause Remedy Reference The power switch on the Turn the power switch to 7 Operation base unit is turned OFF. the base unit ON. Procedures The power switch on the Turn the power switch to...

  • Page 40: Specifications

    11 Specifications Model PS-7 Principle Electrochemical sensor, hot-wire semiconductor sensor, galvanic cell sensor Sampling method Pump suction type (0.5 L/min, suction flow automatically controlled) Gas sampling pipe* Teflon ¼” OD 3/16” ID, maximum tube length 15-30 m. Concentration display 4-digit digital LCD display（incl. units）20-segment bar graph...

  • Page 41: Warranty

    12 Warranty New Cosmos Electric Company Limited, warrants its gas detection products against any defects in materials and workmanship under normal use and operating conditions, for a period of one year from the date of purchase. (Except toxic and oxygen sensor unit) All obligations and liabilities under this product warranty are limited to repairing or replacing at the manufacturer’s...

  • Page 42: Hot-Wire Semiconductor Sensor

    13-2 Hot-wire Semiconductor Sensor In the hot-wire semiconductor method, a semiconductor sensor is designed to measure the change of electrical conductivity initiated by adsorption of the electrons of combustible gases onto the surface of a metal oxide semiconductor heated with a platinum filament. When the semiconductor adsorbs these electrons, the electron concentration increases and the conductivity of the semiconductor rises.

  • Page 43: Galvanic Cell Sensor

    13-3 Galvanic Cell Sensor The galvanic cell sensor consists of noble metal (Pt, Ag) electrode, a base metal (Pb) electrode, and electrolyte. The noble metal electrode contacts the air through a Teflon membrane. Since a potential difference is produced between the two electrodes, the following reaction occurs when a load resistor is connected: O+4e −...

  • Page 44: Glossary

    14 Glossary Gas detector: Detects the gas concentration level, and converts it into an electric signal. Target gases for detection: The target gases for which the gas concentration level is detected, and indications or warnings are given. Detection range: The concentration range within which the level of target gases can be detected, and indications or warnings given.
  • Page 45 Date Revisions GAE-018-00 August 2004 Additional copies of this Operation Manual are available. Contact the following address for ordering information. Manufacturer: New Cosmos Electric Co., Ltd. 2-5-4 Mitsuya-naka Yodogawa-ku Osaka 532-0036, Japan Phone 81-6-6309-1505 Fax 81-6-6309-1514 Distributor: DOD Technologies, Inc...

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