New Cosmos Electric PS-7-M Instruction Manual Download

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PS-7-M series

Extractive Pump Gas Detector

(detachable sensor/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manual will be superseded by your delivery specifications.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-138-00

Feb 2019

Summary of Contents for PS-7-M

Page 1: ...truction 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prior to use This manual describes the standard model If your unit has end user specific options this manual will be superseded by your delivery specifications Instruction Manual No GAE 138 00 Feb 2019 ...

Page 2: ... page 41 Base Unit installation Wiring 6 Installation and Wiring on page 12 Operation 7 1 Operation on page 19 For checking normal operation refer to page 30 Gas Alarm 7 2 Operation Gas Alarm on page 30 Flashing red LED Trouble Alarm 7 3 Operation Trouble Alarm on pages 32 Flashing amber LED Troubleshooting 10 Troubleshooting on page 46 IN OUT Cable entry ...

Page 3: ...Fitting Connection Procedure 18 7 Operation 19 7 1 Operation Procedure 19 7 2 Operation Gas Alarm 30 7 3 Operation Trouble Alarm 32 7 4 Operation Test Mode 34 7 5 Operation Maintenance Mode 35 8 Maintenance 37 9 Consumable Parts Replacement 40 9 1 Filter Element Replacement 40 9 2 Sensor Unit Installation Replacement 41 9 3 Sampling Unit Replacement 44 10 Troubleshooting 46 11 Specifications 48 12...

Page 4: ... e g alarm set values are password protected A manual is provided per system and not per unit 3 PS 7 pyrolyzer s operation manual Doc No GAE 020 xx This document describes installation and replacement procedure for a pyrolyzer sold separately A manual is provided per system if the system includes a sensor unit with pyrolyzer 4 PS 7 M communication specifications guide This document provides commun...

Page 5: ...essary Periodic maintenance is essential to maintain the reliability of your detector Perform periodic maintenance in accordance with the instructions given in this manual PS 7 M series gas detectors are divided into three 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 sold separately...

Page 6: ...hould not be installed in a hazardous area 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 Only use this product in accordance with applicable laws and regulations In the event of a gas leak alarm follow safety procedu...

Page 7: ... Test stick 2 3 Instruction manual this document 1 4 PS 7 gas detector s operation manual for administrators Doc No GAE 019 xx 1 4 PS 7 pyrolyzer s operation manual Doc No GAE 020 xx 1 5 1 Specified during order placement Unspecified orders ship with R1 4 ø6 2 Replacement fuse 3 Two pcs per system 4 One pc per system 5 One pc is provided per system including a sensor unit with a pyrolyzer Note Sen...

Page 8: ...es 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 seneor MF 50 filter unit Gas i...

Page 9: ...rporates a filter element FE 1 that prevents dust from entering the gas inlet and traveling into the sensor 4 Inlet spacer Prevents the filter unit from being over tightened 5 Latch 2 places Latches secure the main unit to the base unit 6 White line 2 places Indicates that the latch is in the lock position 7 Pyrolyzer Refer to PS 7 pyrolyzer s operation manual separate document 8 DIP switches Used...

Page 10: ...ification numeric gas concentration value gas concentration on bar graph trouble status maintenance test mode and flow rate status 5 Operation buttons covered Setting adjustment buttons and TEST switch 6 Front cover Gently pull out and slide 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 ...

Page 11: ...ween the maintenance mode 1 MNT1 maintenance mode 2 MNT2 and normal operation mode 7 Pyrolyzer connector Supplies power to a connected pyrolyzer CDP 7 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 11 RJ 45 jack Connect a LAN cable to the RJ 45 jack 12 Terminal resistor switch Turns on off the termin...

Page 12: ...t When not lit no request from the base unit 1 When the IP address is 0 0000 0000 the IP address can be changed by using a web browser 1 2 4 3 Set the base unit power switch to the OFF position before using the DIP switches to avoid incorrect operation or device failure Do not use IP address 255 1111 1111 because LAN Communication will be disabled if that IP address is used Set the DIP switches in...

Page 13: ...he alarm set values 4 COMM button COMM Imports data from a currently inserted sensor at initial startup etc 5 UP and DOWN buttons UP DOW N Increase decrease the parameter value 6 Analog output check connector CP Dedicated connector to check the unit s 4 20 mA analog output 7 TEST switch TEST Sets the unit to the test mode 8 Button for administrator use Administrator use 9 Communication connector C...

Page 14: ...pinning fast Flow rate is normal FL500 indicated on sub display Spinning slowly Flowrate is reduced Possible filter tube clogging FL400 or less indicated on sub display Stopped Flow rate is too low Low flow rate alarm FL300 or less indicated on sub display 7 Gas concentration on bar graph One bar represents 5 of the full scale value The bar graph value increases from left to right with the far rig...

Page 15: ...emperature changes This product is not drip proof equipment and should be kept away from splashing water Do not block the cooling vents on both sides of the base unit 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 ...

Page 16: ...cts Turn off the gas detector before fuse replacement Keep the connection cables power and signal lines from the detector away from other power lines When wiring place wires to avoid mechanical stress on the wiring Turn off the gas detector before wiring to prevent electric shocks Ensure open collector output is connected TA TC Due to the built in protection diode incorrect polarities will cancel ...

Page 17: ...ielded twisted pair cable B GND ZA1 1st stage gas alarm contact output Dry N O contact Max load 30 VDC 0 5 A resistive load 3 core CVVS cable ZA2 2nd stage gas alarm contact output Dry N O contact Max load 30 VDC 0 5 A resistive load ZC ZA1 ZA2 Common 1 N C Normally Closed N O Normally Open 2 Applicable cable Dia 8 11mm x 2pcs Use appropriate cables for the installation environment Terminal layout...

Page 18: ...he base unit 2 Run power and signal cables thru the grommet located at the bottom of the base unit and connect the cable wires to their corresponding terminals refer to Terminal layout on page 14 6 1 2 Modbus RTU RS 485 Wiring Procedure Establishing Modbus RTU RS 485 communication When using the 24 VDC power supply ensure that the power is 24 VDC 10 When using the PoE power supply ensure that the ...

Page 19: ... point is mandatory When the cable shield from the gas detector is grounded on the power supply side DO NOT ground the shield cable to the Earth terminal located inside the gas detector on the terminal block for power cable to avoid 2 point grounding Requirements for LAN cable Use unshielded twisted pair UTP LAN cable solid wire category 5e or higher Do not use a flat type twisted pair LAN cable I...

Page 20: ...it at later stage move to step 4 4 Ensure that the main unit power switch is in the OFF position 5 To install the main unit pull forward and hold both latches of the base unit Connect the main unit by sliding it onto the rails of the base unit 6 Push the base unit s latches back into place so that the white lines are visible indicating the latches have been locked Ensure that the latches are in th...

Page 21: ...g metal tube fittings may break the gas outlet To prevent this install the provided gas outlet spacer to the gas outlet first then connect the metal tube fitting over the spacer Use metal tube fittings Swagelock SS 6MO 1 4RT or equivalent for both 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 13mm width x 100...

Page 22: ... Is the main unit off Yes Turn off the main unit No Amber TROUBLE LED flashes Change the set values 8 Incorrect sensor unit is inserted Set value change is needed No set value change is needed 14 Initial startup is completed 13 Perform zero adjustment 13 Is this for toxic combustible gas detection 10 Check the set values の確認 No Yes 8 Self test １ Amber TROUBLE LED is off Check the tubing for loosen...

Page 23: ...fic options Pull the center of the plate with finger to remove it from the base unit DIP switches are accessible when the plate is removed Set the base unit power switch to the OFF position before using the DIP switches to avoid incorrect operation or device failure Do not use IP address 255 1111 1111 because LAN Communication will be disabled if that IP address is used When using the 24 VDC power...

Page 24: ...24 VDC 10 When PoE is used Check that the status LED 1 flashes Note The status LED 1 is off when the LAN cable is not securely connected The IP address settable range is 1 0000 0001 to 254 1111 1110 When the IP address is 0 0000 0000 it will be superseded by the IP address set by a web browser Refer to PS 7 M IP address setting guide separate document for IP address change IP address can be set to...

Page 25: ...ift the cover flap open Oxygen sensor COS 7 FS 50vol Toxic gas sensor CDS 7 Combustible gas sensor CHS 7 Oxygen sensor COS 7 FS 25vol Measure the analog output current between the G and H terminals with a multimeter etc If the output level is within the range below go to step 3 If not adjust it using the trimmer Sensor unit model Adjustable range CDS 7 3 92 4 08mA CHS 7 3 92 4 08mA COS 7 17 32 17 ...

Page 26: ...o 6 2 Unit Installation Procedure To center position normal mode Trimmer adjustment screw Rotate the trimmer with a slotted screwdriver to adjust the MNT2 output level G H NOTE Oxygen sensor COS 7 FS 50vol Toxic gas sensor CDS 7 Combustible gas sensor CHS 7 Oxygen sensor COS 7 FS 25vol Analog output 20mA Gas level 4mA 0mA Full scale 0ppm Normal air has an O2 level of 21vol Adjust to 17 4mA Analog ...

Page 27: ...ub display Open the front cover and press the COMM button for more than one second to clear the error When the same type setting of sensor unit is installed e g target gas and full scale value are the same as the previous one go to step 9 9 Good is shown on the sub display The unit will begin a 30 second initialization mode POWER LED flashes then start normal operation mode POWER LED is steady lit...

Page 28: ...e for 1st stage gas alarm contact sec d1 0 d1 0 d2 Delay time 2 Delay time for 2nd stage gas alarm contact sec d2 0 d2 0 az Analog output zero 1 as Analog output span 1 zs Zero or 21vol suppression Suppression percentage against full scale value in 1 increments zs 5 zs 2 H H Gas alarm mode High High limit H H L L L L Low Low limit H L High Low limit Con Broken pyrolyzer wire detected 0 Detected 1 ...

Page 29: ... 10 ppm 11 Check for the correct sampling gas flow rate Check that the flow rate icon quickly spins and the amber TROUBLE LED is off When the flow rate icon is quickly spinning the specified flow rate 500mL min is maintained On sub display Default set value Description A1 Toxic CDS 7 Combustible CHS 7 A1 10 10 of full scale value O2 COS 7 A1 72 72 of full scale value A2 Toxic CDS 7 Combustible CHS...

Page 30: ...ly Refer to 9 2 Sensor Unit Installation Replacement Check that the latches are in the fully locked position white lines visible Connect the tube back to the gas inlet Check that the flow rate icon quickly spins Block gas inlet Clogging notification The flow rate icon slowly spins when the flow rate is reduced less than 400mL min indicating a possible clogged tube filter or excessive negative pres...

Page 31: ...ng Operation for more information Depending on the environment it may take longer than the expected 24 hour 7 day period see above for the base line zero or 21vol to be fully stabilized For COS 7 oxygen sensor FS 50vol one touch 21vol adjustment is not possible However if 21vol adjustment is needed refer to PS 7 gas detector s operation manual for administrators for the procedure separate document...

Page 32: ...nds The green POWER LED will flash one time indicating the zero adjustment is completed Press the SPAN button for more than 4 seconds The green POWER LED will flash one time indicating the zero adjustment is completed Oxygen sensor COS 7 Toxic gas sensor CDS 7 Combustible gas sensor CHS 7 POWER LED ZERO button SPAN button Set to the center position Lift the cover flap open Gas concentration with u...

Page 33: ...arm contacts will automatically return to their normal positions status The table below lists the operation of each mode in the event of a gas alarm 1st stage gas alarm 2nd stage gas alarm Normal operation gas monitoring Trouble alarm internal failure 1st stage gas alarm 2nd stage gas alarm LED Green lit Amber flash Red flash Red flash LCD Gas alarm contact ZA1 OFF open position OFF open position ...

Page 34: ...rm contact ZA1 activates Alarm set value shown as A2 25vol Reading in normal ambient air no gas detected 21vol 0vol Low limit of gas alarm ALARM1 is lit Gas alarm contact ZA1 activates Alarm set value shown as A1 High limit of gas alarm ALARM2 is lit Gas alarm contact ZA2 activates Alarm set value shown as A2 50vol Reading in normal ambient air no gas detected 21vol 0vol 2nd stage gas alarm ALARM1...

Page 35: ...s on the LCD in the following situations the sensor s zero level output is extremely low a broken sensor wire is detected This applies to combustible gas sensor CHS 7 only 3 Incorrect sensor installed The data e g target gas type full scale value from the last installed sensor has been recorded by the gas detector If a newly installed sensor unit does not match the gas detector will detect that an...

Page 36: ...ff Off 7 Memory read error nG On Flashing Off Error code shown on the sub display Oxygen sensor COS 7 The analog output from this product falls to 0 6mA or less in the event of a trouble alarm as listed above When the host system e g control room is set to the low limit alarm gas alarm activates when the gas concentration falls to the alarm set value or less and If the product s analog output fall...

Page 37: ...evices release the interlocks beforehand as needed to prevent a possible activation of the interlocks during the test mode or enter the maintenance mode before entering the test mode then release the interlocks of the external devices beforehand as needed Refer to 7 5 Operation Maintenance Mode for more information Notify those concerned before starting the gas alarm test While in maintenance mode...

Page 38: ... the amber TROUBLE LED will flash and the detected gas concentration will be shown on the LCD Gas alarm contact Trouble alarm open collector Analog output Amber TROUBLE LED On display MNT1 host maintenance mode 3 Disabled fixed at OFF Disabled 1 fixed at ON Output corresponding to the detected gas concentration Flashing Detected gas concentration value MNT2 Disabled fixed at OFF Disabled 1 fixed a...

Page 39: ... are used to operate the interlocks of the external devices release the interlocks beforehand as needed to prevent a possible activation of the interlocks during the maintenance mode When switching the maintenance switch from MNT1 to MNT2 or vise versa the gas detector briefly enters the normal operation mode If switching is done while an alarm condition exists an alarm signal will be output If th...

Page 40: ... for at least 3 years Example of the check inspection results is on page 39 Inspection Contents and Frequency Check item Startup or relocation Periodic Inspection Routine check Every 6 months Every 3 years 1 Concentration display V V V 2 Sampling gas flow rate V V 3 Airtightness V V 4 Filter element V 5 Tubing V 6 Sensor unit installation replacement V V 7 Sampling unit replacement V 8 Loop check ...

Page 41: ...The filter element is likely to clog faster in severe environment If the clogging notification flow rate icon slowly spins or stops appears on the LCD check the filter element Replace it with a new one if it is dirty Refer to 9 1 Filter Element Replacement for procedure 5 Tubing Check that tubing has been done correctly at startup or relocation If the tubing is incorrect gas sampling from the targ...

Page 42: ... element Tubing Replaceme nt sensor No Replace sampling unit Before adj After adj 1st stage 2nd stag e 1 Cabinet 0 0 50 100 H1021943 2 Device A 0 0 5 10 H1021944 3 4 5 To maintain the reliability of the gas detector perform a gas alarm test by using TEST switch etc at least once a month While in test mode alarm test using TEST switch the gas alarm contacts activate If the gas alarm contacts are us...

Page 43: ...rate the filter unit s top from the inlet 2 Replace the filter element with a new one 3 Install the filter unit top to the inlet Rotate and tighten the nut to secure the tube Ensure O ring is correctly seated Tips when removing reinstalling the entire filter unit from into the gas inlet Completely remove old sealing tape no residue Wrap new sealing tape around the threads of the filter unit approx...

Page 44: ...F position will turn off the trouble alarm output open collector If the trouble alarm output is used to operate the interlocks of the external devices release the interlocks beforehand as needed to prevent a possible activation of the interlocks during replacement Check that the target gas type and full scale value are correct before using a new sensor unit Also check that the sensor unit expirati...

Page 45: ...forward slightly Hold the sensor unit by its sides then pull it out of the main unit 5 Insert a new sensor unit Install the rear cover Insert a finger so that the sensor unit will tilt forward If the sensor unit is not completely inserted an airtight seal will not be created and correct gas detection will not be possible Press here then pull back the rear cover Push with palm to insert the sensor ...

Page 46: ...icating the latches have been locked Ensure that the latches are in the fully locked position white lines visible Normal detection is not possible if latches are not fully locked Dispose of used sensor sampling units in accordance with applicable local laws and regulations NOTE Push the latch lock position White line Latch Rail 2 Align with the rail and slide on 1 Pull forward and hold the latches...

Page 47: ...he gas detector prior to sampling unit replacement Setting the main unit power switch to the OFF position will turn off the trouble alarm output open collector If the trouble alarm output is used to operate the interlocks of the external devices release the interlocks beforehand as needed to prevent a possible activation of the interlocks during replacement Press with thumbs Disconnect the connect...

Page 48: ...nstallation Replacement If the sensor unit is not completely inserted an airtight seal will not be created and correct gas detection will not be possible Take care that the cables should not be caught between the front panel and sampling unit Dispose of used sensor sampling units in accordance with applicable local laws and regulations NOTE Rear cover Front panel Ensure cables are not caught ...

Page 49: ...ctor to the front panel is loose Securely connect the connector 9 3 Sampling Unit Replacement Blown fuse Replace the fuse Turn off the detector before replacement 5 3 Base Unit Amber TROUBLE LED flashes Low flow rate due to clogged filter element Replace the filter element 9 1 Filter Element Replacement Low flow rate due to pump failure Replace the sampling unit 9 3 Sampling Unit Replacement Low f...

Page 50: ...ero suppression set value or 2 Change the zero suppression set value 1 7 4 Operation Test Mode 2 PS 7 gas detector s operation manual for administrators Flow rate icon slowly spins Low flow rate due to clogged filter element Replace the filter element 9 1 Filter Element Replacement Low flow rate due to pump failure Replace the sampling unit 9 3 Sampling Unit Replacement Low flow rate due to clogge...

Page 51: ... reaches 18vol with a 10vol concentration at 20 C 2 C Excludes delay time caused by piping length and communication time Alarm indication Gas alarm 2 stages Red LED flashes ALARM1and or ALARM2 shown on display Filter element replacement notification Flow rate icon slowly spins on display Low flow rate alarm with 10 second delay time Amber LED flashes FLOW shown on display Flow rate icon stops Sens...

Page 52: ...able Dia 8 11mm x 2 pcs Operating conditions Temperature 0 C to 40 C No sudden temperature change Humidity 30 to 85 RH No condensation Approvals EMC 2014 30 EU 5 RoHS 2011 65 EU Power supply 24 VDC 10 or Power over Internet PoE IEEE 802 3af ANSI X3 263 Power consumption 4 Combination CDS 7 COS 7 CHS 7 CDS 7 CDP 7 Typ Max Typ Max Typ Max Typ Max 24 VDC gas concentration analog output used 2 3 W 4 7...

Page 53: ... to a manufacturing defect during the warranty period and used in accordance with the instruction manual and specifications we will provide a free replacement and repair service This warranty covers the New Cosmos product parts only and not third party product parts 2 Warranty Exclusions The following will be repaired at the cost of customer even during the warranty period 1 Failures and damages i...

Page 54: ...erential voltage using a bridge circuit This type of sensor is very sensitive and can detect combustible or toxic gases at a low ppm or even a ppb level 15 3 Catalytic Sensor CHS 7 CS Catalytic combustion occurs on the catalytic layer applied on a platinum coil even if the gas concentration is well below the lower flammable limit LFL This causes a rise in temperature of the platinum coil and incre...

Page 55: ...an the alarm set value or to some other specified conditions Calibration gas test gas Gas specifically prepared to calibrate adjust the gas detection and alarm system Hazardous area An area in which an explosive atmosphere is present or may be expected to be present in quantities such as to require special precautions for the construction installation and use of electrical apparatus Non hazardous ...

Page 56: ...e Additional copies of this instruction manual may be purchased Contact New Cosmos or its authorized representative for ordering Authorized representative Manufacturer NEW COSMOS ELECTRIC CO LTD 2 5 4 Mitsuya naka Yodogawa ku Osaka 532 0036 Japan URL http www new cosmos co jp ...

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