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INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™

Page 10 of 48

1.4.

E

XTENDED

(D

UAL

) R

ANGE

O

PTION

1.4.1.

Operation

When the measuring range of the analyzer is larger than 1150BTU/SCF, an extended range

option is available which covers a Wobbe index of 2850.BTU/SCF. This is accomplished by

adding a second gas-mixing orifice and selection valves to make changeover possible.

The dilution ratios of each mixing orifice are chosen such that the measuring ranges overlap.

Via the software it is possible to create a 4/20mA current loop signal that covers the whole range.

It is necessary to establish a switch over point that must be calibrated.

For this reason the calibration system is expanded with an extra solenoid valve.

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Summary of Contents for 9610

Page 1: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 GENERAL PURPOSE EXPLOSION PROOF Version 1 4 2 Revision date June 7th 2019 CAL 01 D 9826 ...

Page 2: ...E mail sales cosaxentaur com http www cosaxentaur com Copyright 2019 All rights reserved The contents of this publication are presented for informational purposes only While every effort has been made to ensure this document error free it should not be construed as warranties or guarantees expressed or implied regarding the product or services described herein or its use or applicability COSA Inst...

Page 3: ...ERAL 16 2 2 STORAGE 16 2 3 PLACEMENT 16 2 3 1 General 16 2 3 2 COSA 9610 in general purpose execution Type 01 02 17 2 3 3 COSA 9610 in explosion proof execution Type 01 Ex 02 Ex 17 2 4 MECHANICAL CONNECTIONS 18 2 4 1 General 18 2 4 2 Sample supply 19 2 4 3 Calibration gasses 19 2 5 ELECTRICAL CONNECTIONS 20 2 5 1 COSA 9610 in general purpose execution 20 2 5 2 COSA 9610 in explosion proof executio...

Page 4: ...u 34 3 3 6 System Menu 36 3 3 7 Display Menu 37 3 3 8 Reset Alarms Menu 38 3 4 TEMPERATURE CONTROLLED OVEN 39 3 4 1 Furnace temperature control unit 39 3 4 2 Adjustment procedure temperature regulator 40 4 PREVENTIVE MAINTENANCE 41 4 1 WEEKLY MONTHLY MAINTENANCE 41 4 1 1 Compressor optional 41 4 1 2 Filters 41 4 2 THREE 3 MONTH MAINTENANCE 41 4 2 1 Compressor optional 41 4 3 ANNUAL MAINTENANCE 42 ...

Page 5: ...remaining oxygen in the flue gas will change simultaneously By measuring the concentration of oxygen in the flue gas after calibrating the instrument with two gasses with known Wobbe index the Wobbe index can be calculated 1 2 THE COSA 9610 ANALYZER The COSA 9610 features fast response time and high accuracy These features make it unique over conventional Wobbe index analyzers The oxygen concentra...

Page 6: ...is is mounted such that one side is in contact with the outside air and the other side with the flue gasses At high temperatures 600ºC O2 ions in the ZrO2 grating become mobile through vacancies therein By fixing porous Pt electrodes at both sides of the ZrO2 O2 gas molecules can through diffusion by and uptake of two electrons from the Pt electrode enter the ZrO2 as O2 ion move to the other elect...

Page 7: ...ill at surrounding temperatures however as long as gas and air fluctuate to the same extent this hardly influences the mixing proportion In case of large surrounding temperature fluctuations the calibration sequence has to be performed more often Hereafter gas and air are mixed in the mixing chamber The mixing chamber is equipped with orifices in the inlet nozzles The gas and airflow are determine...

Page 8: ... to the analyzer The operator controls the timing Automatically The analyzer itself controls the timing of the valves switching When the measured values stay within the specified tolerances the newly calculated calibration parameters will be accepted Otherwise the analyzer will keep the old value and generates a CAL ERROR on the display and switch the system fault contact and calibration fault con...

Page 9: ...xternal host to prepare for calibration validation 3 Process gas is switched off and the low calibration gas is switch on 4 The analyzer waits for the readings to stabilize up to the Switch Time 5 Low calibration gas is switched off and the medium calibration gas is switched on 6 The analyzer waits for the readings to stabilize up to the Switch Time 7 The analyzer switched the gas stream to the hi...

Page 10: ...BTU SCF This is accomplished by adding a second gas mixing orifice and selection valves to make changeover possible The dilution ratios of each mixing orifice are chosen such that the measuring ranges overlap Via the software it is possible to create a 4 20mA current loop signal that covers the whole range It is necessary to establish a switch over point that must be calibrated For this reason the...

Page 11: ... 20 mA outputs 4 outputs total optional Span and service selectable Display Optional Digital Output 8 User programmable contact relays Safety General area or Explosion proof Wobbe w o density cell or with streaming S G option 1 5 2 Utilities Power supply 110 VAC 50 60 Hz or 230 VAC 50 Hz Power consumption 430 VA maximum Instrument air 0 353 SCF min analyzer at 3 barG 43psig 0 706 SCF min purge sys...

Page 12: ...ion of the standard information for setup and operation of a system such as purge time flow rates pressures and enclosure size are easily programmable Additional features allow Class I and Class II operation inputs for system bypass enclosure power on off temperature overload and activation of Rapid Exchange flow for cooling or auxiliary relay for separate cooling source delay power shutdown and m...

Page 13: ...2 auxiliary contacts power supply module galvanically isolated barriers for the inputs vent s and temperature modules all stackable and easy to remove and install into the explosion proof enclosure that houses them The power supply module is available in 24 VDC or 100 240 VAC units The enclosure power contacts are forced guided safety relays The auxiliary contacts can be user configured for differ...

Page 14: ... dust atmospheres require the following 1 removing the dust 2 sealing the enclosure and then 3 purging the enclosure After these sequences the pressure within the enclosure is above the minimum level The equipment within the enclosure can be energized Purge Timing When using the X Purge in a gas or gas and dust location the time for purging an enclosure can be based either on a known purge rate an...

Page 15: ...ng the dynamic purge time the user interface will display the purge time in a percentage starting with 0 and ending with 100 purge time complete Purging Modes Purging start up can be set up in 4 different modes which are explained below STD Standard mode requires the operator to engage the manifold solenoid valve manually when purging and manually disengage when a successful purging is complete SA...

Page 16: ...e vent has a pressure transducer and thermal flow sensor that is connected to the 6000 EPCU and is intrinsically safe through the galvanic isolation barrier within the EPCU Because measurement of the flow is always at the exhaust of the pressurized enclosure the vent is located on the enclosure s such that it is venting to the atmosphere The vent is connected to the I S termination board using the...

Page 17: ...seblock Rd sales cosaxentaur com Yaphank NY 11980 Tel 631 345 3434 Fax 631 345 5349 We kindly ask you to submit photographs of the damage If the COSA 9610 is supplied by the COSA XENTAUR CORPORATION as part of a complete package and built into a shelter or house installation may differ from hereunder described 2 2 STORAGE The COSA 9610 must be stored frost free and at a maximum temperature of 122º...

Page 18: ...e floor or underneath located obstacles that the oven drain can be connected to a drain header or a condense bottle The COSA 9610 is supplied on a 304SS freestanding frame This frame is to be placed on a flat surface i e concrete slab Two holes in the base of the frame enable the COSA 9610 to be fixed to the floor 2 3 3 COSA 9610 in explosion proof execution Type 01 Ex 02 Ex The COSA 9610 is suppl...

Page 19: ...nstrument air to remove all particles All connections must be checked against leakage prior to putting the analyzer in operation or installing the tubing Pressurize the lines with nitrogen or instrument air at 7bar maximum to perform leak test Check each connection with soap e g snoop Make sure before pressurizing for leak test that the power to the analyzer is off sample and calibration selection...

Page 20: ...to keep the gas above dew point Check your sample data for required temperature Sample inlet connection on the analyzer is identified with a tag plate The sample connection on the analyzer is for 1 8 OD tubing Tubing size to the process may require a different tube size this should be determined taking into account process pressure sample line length and acceptable lag time 2 4 3 Calibration gasse...

Page 21: ...e cables are foreseen for ATEX use and suitable conduit and conduit adapters for North American installation If more entries are required only suitably certified cable glands or conduit adapters are allowed to be used and it has to be made sure that they are in good electrical contact with the white personated sink layer on the electronics enclosure surface paint locally to be removed with a deter...

Page 22: ...Vdc Analog signals The COSA 9610 has two 4 20mA analog outputs 4 optional The signals can be user programmed to represent various measurement readings such as Wobbe index and CARI index The analog output signals are wired via isolating barriers Please note that these barriers are to be connected to an intrinsic safe earth I S When no intrinsic safe earth is available the barriers may be connected ...

Page 23: ...tube can now be connected Because the supply line is under pressure and has been closed off on the COSA 9610 side the connecting fittings can be squirted with soap in order to detect any possible leaks When bubbles appear this indicates a leak and the tube concerned must immediately be closed off at the supply point Inspect the fitting and tube replace components when necessary 3 1 2 Air orifice s...

Page 24: ...djusting booster relays Set the chosen residual O2 set point with help of the booster relay With the booster relay it is possible to give a small negative i e the gas pressure is higher than the air pressure or positive offset of max 0 5 bar as set point correction or as pressure drop compensation over the air and gas tubes in the heat exchanger In order to achieve the necessary offset pressure th...

Page 25: ... assembled and then checked for leakage by means of either a gas leak detector or soap It is advisable to carry out a check on the booster relay adjustment with high Wobbe Index calibration gas directly after setting up the booster set point Using the on screen menu select 2 Points manual Dual Range manual for dual range analyzer validation Proceed to the Wait for cal gas 2 to stable step Wait for...

Page 26: ...revious menu Undo value change Go up one menu item Go down one menu item Go to previous item value Go to next item value To enter the main menu screen press or the Esc The screen now presents some functions that can be selected by the cursor keys or by typing the number associated to the menu item To resume normal operation press or Esc until the main screen to appear To change a setting value on ...

Page 27: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 26 of 48 ...

Page 28: ...process stream 2 selected Stream sw Status switching streams High alarm High Calorific value Low alarm Low Calorific value Calibrate Calibration in progress Validate Validation in progress Calibration fault Calibration fault Sys fault Collective alarm In op Analyzer is in operation System Ok Status box also displays access level and fault Explanation inputs Calibration req External input to start ...

Page 29: ...t manual 4 Settings 1 Gas 1 Wobbe 2 1 point manual 3 2 point manual 5 Schedule 1 Semi automatic 2 Gas 1 CARI 3 Gas 1 Specific 3 2 point manual 4 Dual range manual 4 Dual range 1 Sunday 2 Remote Gravity manual 2 Monday 3 Timed 4 Gas 2 Wobbe 3 Tuesday 4 Timed Method 5 Gas 2 CARI 6 Gas 2 Specific 4 Wednesday 5 Start Delay Gravity 2 Operation 1 General 5 Thursday 6 Switch Time 7 Gas 3 Wobbe 6 Friday 7...

Page 30: ...tem 1 About 2 Date Time 3 Login 7 Display 4 Password 1 Chart 1 User Password 1234 8 Reset Alarms 2 Chart 2 5 Logout Admin Password 9999 3 Color 6 Configuration 7 Test 8 Restart 1 Analog Output A 9 Exit 2 Analog Output B 3 Analog Output C 4 Analog Output D 5 Digital Output 1 8 6 Digital Output 9 16 7 Digital Input 8 Digital Out Polarity 1 8 9 Digital Output Polarity 9 16 0 Digital Input Polarity ...

Page 31: ...raph numbers correspond with the key sequence from the menu tree In this way it is easy to see how a specific menu is reached One exception is the measuring menu this is reached from the main screen by either the or Enter key 3 3 1 Calibration Menu In the main menu the following sub menus are available ...

Page 32: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 31 of 48 3 3 2 Operation Menu ...

Page 33: ...age 32 of 48 3 3 3 Measurement Menu 3 Measurement 1 Wobbe 2 Calorific Value 3 CARI 4 Specific Gravity 5 Density 6 Residual Oxygen 7 Temperature 8 Pressure 1 Oven 9 Flow 1 Sample System 2 Sample System 0 Sulfur 2 Instrument Air 3 Oven Inlet A H2 4 Oven Outlet ...

Page 34: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 33 of 48 3 3 4 Output Menu ...

Page 35: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 34 of 48 3 3 5 Communications Menu Submenus 1 3 with default communication settings ...

Page 36: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 35 of 48 ...

Page 37: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 36 of 48 3 3 6 System Menu Passwords USER 1234 ADMIN 9999 ...

Page 38: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 37 of 48 Display Menu ...

Page 39: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 38 of 48 3 3 7 Reset Alarms Menu ...

Page 40: ...solid state relay which in its turn controls the on off ratio of the voltage to the heater element To generate alarms and to enable the system to compensate for temperature changes The oven temperature is controlled by software included in the operating system of the analyzer All settings are factory programmed but may need to be fine tuned depending on local conditions However for servicing purpo...

Page 41: ... the setting of the temperature controller The controller measures the temperature with the help of a K type thermocouple The heating is arranged by a pulsing 5VDC signal The on off relation decides the added capacity The tuning program in the regulator will optimize the regulator algorithm This program decides the most optimal settings for the PID regulation Procedure 1 Check the connections acco...

Page 42: ...king switch and make the buffer vessel pressure less using the de aeration dewatering valve Both filter housings can now be loosened after which the filter elements can be changed Replacement of the two intake filters Disconnect mains supply and dismantle the upper half of the compressor housing being careful that the ventilator cable plug does not come loose from the ventilator Using a screwdrive...

Page 43: ...ENANCE Check the calibration gas bottles for pressure Check the sample system for correct pressure Check the bypass flow meter for correct flow rate Replace the instrument air filters as required Replace optional sample gas filters as required Replace optional pump diaphragms as required ...

Page 44: ...ntroller 0 5 VDC to Solid State Relay Contact supplier Check pulsating voltage 0 60 VAC to oven Contact supplier Check oven resistance 13 Contact supplier Analyzer becomes slow 20 seconds response time Check system flows and gas pressures Clean system and or adjust to correct values Check resistance of cell when sample gas is shut off it should be lower than 1000 Replace Zirconia cell No response ...

Page 45: ...t no physical injury can occur caused by coming into contact with any parts which may still be hot 1 Remove the connecting clips from the sensor and take care that the ceramic ring stays in place 2 Unscrew the sensor from the cell holder 3 Then draw the sensor out of its holder taking care that the sensor does not come into contact with dirt grease or oil The sensor is dismantled in the following ...

Page 46: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 45 of 48 5 INSTALLATION DRAWING ...

Page 47: ...s COSA INSTRUMENT CORPORATION New York Texas Corporate Headquarters Manufacturing Offices Sales Service Offices 84F Horseblock Rd 4140 World Houston Parkway Yaphank NY 11980 Suite 180 Tel 631 345 3434 Houston TX 77032 Fax 631 345 5349 Tel 713 947 9591 Fax 713 947 7549 E mail sales cosaxentaur com Web http www cosaxentaur com WARNING Substitution of components may impair hazardous location safety L...

Page 48: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 46 of 48 ...

Page 49: ...een examined against the following standards 1 ATEX EN 60079 0 2009 EN 60079 2 2007 EN 60079 11 2007 EN 60529 A1 2000 2 US CANADA FM3600 1998 FM3610 2010 FM3810 2005 FM3620 2000 ANSI NEMA 250 1991 ANSI 1EC 60529 2004 ANSI NFPA 496 2003 CSA C22 2 No 0 4 1999 CSA C22 2 No 157 2006 CSA C22 2 No 60529 2005 3 IECEx IEC 60079 0 2011 IEC 60079 2 2007 IEC 60079 11 ...

Page 50: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 48 of 48 ...

Page 51: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL COSA 9610 Page 48 of 48 ...

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