cosams - Analox Sensor Technology

cosams - Analox Sensor Technology
COSAMS
User Manual
Analox Military Systems
15 Ellerbeck Court, Stokesley Business Park,
North Yorkshire, TS9 5PT, UK
T: +44 (0)1642 711400 F: +44 (0)1642 713900
W: www.analoxmilitarysystems.co.uk E: [email protected]
COSAMS
User Manual
Document ref: P0138-810-09
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User Manual
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Table of Contents
1
Introduction .......................................................... 9
2
Modification state control .................................... 10
3
System checklist .................................................. 12
4
Transport and storage considerations ................. 13
5
Installation details............................................... 14
5.1
Overview ................................................................... 14
5.1.1
5.2
Mechanical installation .............................................. 15
5.2.1
5.3
6
7
Tools/consumables required for installation ................... 15
Mounting COSAMS in the accommodation area (forward
compartment) ........................................................... 15
Electrical installation ................................................. 20
5.3.1
Cable identification ..................................................... 20
5.3.2
Signal output ............................................................. 21
5.3.3
Equipotential bonding strap ......................................... 21
Technical description ........................................... 22
6.1
Gas sampling............................................................. 22
6.2
Power supply ............................................................ 24
6.3
Power distribution .................................................... 24
6.4
CO sensor .................................................................. 24
6.5
Interface PCB ............................................................ 24
6.6
SDA operator console ................................................ 25
6.7
SDA output module ................................................... 25
6.8
Electrical schematic .................................................. 26
Operating instructions ......................................... 27
7.1
Controls .................................................................... 27
7.2
Start-up .................................................................... 27
7.3
Warm-up ................................................................... 28
7.4
Normal operation ...................................................... 28
7.4.1
7.5
System status indicator .............................................. 29
Menu ......................................................................... 29
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7.5.1
Adjusting the backlight ............................................... 30
7.5.2
Auto-zero function ..................................................... 31
7.5.3
Replacing catalyst ...................................................... 31
7.5.4
Resetting the service interval timer .............................. 31
7.5.5
COSAMS information .................................................. 31
7.5.6
Data logging.............................................................. 32
Calibration ........................................................... 36
8.1
9
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Zero and span calibration .......................................... 36
8.1.1
Performing a zero calibration ....................................... 36
8.1.2
Performing a span calibration ...................................... 36
Alarms ................................................................. 38
9.1
Adjusting alarm set points ........................................ 38
9.2
Acknowledging alarms .............................................. 39
9.3
Clearing alarms and hysteresis ................................. 39
10
Technical in-service support software ................. 40
11
Troubleshooting................................................... 41
11.1 Fault announcement ................................................. 41
11.2 Fault diagnosis .......................................................... 41
11.3 Fault logging ............................................................ 41
12
Maintenance ........................................................ 44
12.1 Spare parts ............................................................... 44
12.2 Special maintenance equipment ................................ 45
12.3 Periodic maintenance ................................................ 46
12.3.1 Filter check and replacement ....................................... 49
12.3.2 Auto-zero catalyst replacement ................................... 50
12.3.3 Cabinet breather inspection/replacement ...................... 50
12.3.4 Removal and replacement of the baseplate assembly ..... 51
12.3.5 Sample pump replacement .......................................... 53
12.3.6 Infra-red source replacement ...................................... 55
12.4 Non-periodic maintenance ........................................ 56
12.4.1 Replacing the power supply unit .................................. 56
12.4.2 Solenoid valve replacement ......................................... 58
12.4.3 Flow switch replacement ............................................. 59
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12.4.4 Replacing the SDA Output Module PCB ......................... 60
12.4.5 Replacing SDA Operator Console membrane label .......... 61
12.4.6 Replacing the SDA Operator Console ............................ 62
12.4.7 CO sensor calibration ................................................. 63
13
Warranty ............................................................. 66
14
Fault reporting to Analox ..................................... 67
15
Specifications ...................................................... 68
15.1 Mechanical specifications .......................................... 68
15.2 Electrical specifications ............................................. 68
15.3 Environmental specifications .................................... 68
15.4 Performance specifications ....................................... 69
16
Disposal ............................................................... 70
16.1 WEEE statement ........................................................ 70
16.2 Catalyst disposal ....................................................... 70
17
Declaration of Conformity .................................... 71
Appendix - Nanaucat safety data sheet....................... 72
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List of Figures
Fig 1:
Cabinet modification state label ................................ 10
Fig 2:
Baseplate modification state label ............................ 11
Fig 3:
COSAMS overview ..................................................... 14
Fig 4:
Mounting arrangement in the accommodation area .. 15
Fig 5:
Shock isolator mounting points ................................. 16
Fig 6:
Shock isolator preparation ........................................ 16
Fig 7:
Relative positions of COSAMS shock isolator mounting
points and suggested cut-out to provide clearance around
electrical connectors .................................................................. 17
Fig 8:
Mounting arrangement in the engine room ............... 18
Fig 9:
room
Relative positions of COSAMS mounting holes in engine
19
Fig 10:
COSAMS internal pneumatic arrangement ................. 22
Fig 11:
COSAMS internal electrical arrangement ................... 23
Fig 12:
Internal wiring schematic ......................................... 26
Fig 13:
COSAMS front panel .................................................. 27
Fig 14:
Start-up splash screen .............................................. 27
Fig 15:
Warm-up screen ........................................................ 28
Fig 16:
Main display overview ............................................... 28
Fig 17:
The main menu ......................................................... 29
Fig 18:
The backlight sub-menu ............................................ 30
Fig 19:
Zeroing sensor indication .......................................... 31
Fig 20:
COSAMS information screen ...................................... 31
Fig 21:
Example of data logged by system ............................ 32
Fig 22:
Span adjustment ....................................................... 37
Fig 23:
Example of alarm set-point adjustment .................... 38
Fig 24:
Alarm hysteresis ....................................................... 39
Fig 25:
Fault indication (example of a flow fault) ................. 41
Fig 26:
COSAMS internal components (1) ............................. 47
Fig 27:
COSAMS internal components (2) ............................. 48
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Warnings, cautions and notes
Warnings and Cautions are used in this Manual to highlight potential hazards and safety
risks. Notes are used to provide supplementary information that is not hazard-related.
WARNING:
THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT,
IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
CAUTION:
THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT,
IF NOT AVOIDED, COULD RESULT IN EQUIPMENT DAMAGE OR
LOSS OF DATA.
NOTE:
THIS INDICATES INFORMATION THAT IS CONSIDERED
IMPORTANT BUT IS NOT HAZARD RELATED.
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Safety information
Please read this manual prior to installing and using the Analox COSAMS, paying
particular attention to the following safety information:
WARNING:
MAINS VOLTAGE IS PRESENT WITHIN THE COSAMS. DISCONNECT
THE POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE
WITHIN THE CABINET.
WARNING:
HIGH PRESSURE GAS SUPPLY MUST NOT BE APPLIED TO EITHER
OF THE COSAMS GAS PORTS. TO DO SO MAY RESULT IN DAMAGE
TO THE COSAMS SYSTEM AND THE POSSIBLE EMISSION OF
PROJECTILES. GAS PRESSURE AT THE INLET PORT MUST NOT
EXCEED 500HPA (GAUGE PRESSURE). DO NOT OBSTRUCT THE
EXHAUST PORT.
WARNING:
THE COSAMS CONTAINS A SMALL QUANTITY OF NANAUCAT
CATALYST WHICH MUST BE REPLACED DURING ROUTINE
SERVICING. THIS MATERIAL MAY CAUSE IRRITATION OF THE
EYES, NOSE, THROAT AND SKIN BUT UNDER NORMAL
CIRCUMSTANCES AN OPERATOR/TECHNICIAN WILL NOT COME
INTO CONTACT WITH THIS MATERIAL. A MATERIAL SAFETY
DATASHEET (MSDS) IS INCLUDED IN THE APPENDIX.
WARNING:
SOME COMPONENTS OF THE GFC CO SENSOR, MOUNTED WITHIN
THE COSAMS CABINET, ARE CONTROLLED TO 50°C DURING
NORMAL OPERATION OF THE SENSOR. THE SENSOR SHOULD BE
ALLOWED TO COOL A LITTLE BEFORE HANDLING.
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Introduction
This manual details installation, operation and maintenance of the Analox COSAMS
carbon monoxide (CO) sensor, developed for the submarine atmosphere monitoring
system.
Each submarine is to be fitted with two COSAMS units; one mounted to the fore, in the
accommodation area, and the other, aft, in the engine room.
Each COSAMS indicates the local CO concentration on a colour LCD and transmits a
corresponding 4-20mA signal to the submarine’s Central Air Monitoring System.
The COSAMS user interface permits calibration of the sensor and may be used to
provide a local visual alarm, if desired.
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Modification state control
Each instrument is fitted with a serial number plate, as shown below:
Fig 1: Cabinet modification state label
The first COSAMS delivered will initially have no modification numbers crossed out, this
is interpreted as “Modification State 0”.
As design changes are made that affect the form or function of the instrument, the
Modification Record boxes will be used to track changes made to individual units. For
example, as an instrument receives the first authorised modification it will have the ‘1’
box crossed out, signifying that it is now at modification state 1.
Design changes that are applied to ALL delivered instruments in a controlled and timely
manner may be done without updating the modification record; the purpose of the
modification record is to signify the differences between instruments.
Modification state
Date authorised/DCN
No
0
1
2
Details
First article delivery
07/08/2015
DCN2015-0049
DCN2015-0041
Auto zero time updated, fault codes updated
DCN2015-0080
SDA serial number now XXXX-xxx (Where XXXX is the
SDA serial and xxx is the cabinet serial)
DCN2015-0069
DCN2015-0111
DCN2015-0122
Captures software changes required to improve the
method of calculation used to determine warmup period
on startup and add fault codes for situations where NFF
was previously displayed as the code.
Captures change made to use a value lower than 2mA
for fault condition as opposed to 22mA on the 4-20mA
output. As per 226345023 - Agreement of Change No.2
ver1 (Analox ref Contract Variation ref S050035 CV102)
Internal wiring change, new ITT Cannon 7 way
connector for connection to baseplate
Captures an improvement to the firmware to ensure
pump is not turned off during an auto zero when using
new interface board.
Table 1: Cabinet modification state
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The baseplate is fitted with a modification state label as shown below:
Fig 2: Baseplate modification state label
As design changes are made that affect the form or function of the instrument, the
Modification Record boxes will be used to track changes made to individual units. For
example, as an instrument receives the first authorised modification it will have state
‘01’ after MOD State, signifying that it is now at modification state 1.
Design changes that are applied to ALL delivered instruments in a controlled and timely
manner may be done without updating the modification record; the purpose of the
modification record is to signify the differences between instruments.
Modification state
Date authorised/DCN
No
0
1
First article delivery
Not released to NDLO
DCN2015-0082
2
Details
30/09/2015
DCN2015-0111
3
DCN2015-0111
MOD01 baseplate, 5S3 replaced with COSAMS interface
PCB, new flow switch, PEM inserts added to aid
assembly.
MOD02 baseplate, Output module now on upright, new
spacers for interface PCB and OM PCB, pump now on
upright.
MOD03 baseplate, OM PCB now on underside, pump now
secured with clamp, pump head rotated 90°, better
cable tie mounts added (PEM) and pipework updated,
PEM studs for mounting GFC sensor added, oval
grommets added for easier wiring.
Table 2: Baseplate modification state
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System checklist
Each system, suitable for fitting out one submarine, comprises the following items:
Item
Description
1.
2 x COSAMS instrument
2.
4 x shock isolator for installation in accommodation area
3.
1 x shock mount fixing kit
4.
2 x power input connector (One per COSAMS)
5.
2 x signal output connector (One per COSAMS)
6.
2 x enclosure locking key (One per COSAMS)
7.
2 x 2m length of calibration sample tube (One per COSAMS)
8.
2 x USB lead (One per COSAMS)
9.
2 x COSAMS software CD (One per COSAMS)
10.
2 x User Manual (One per COSAMS)
11.
2 x Electrical schematic – P0138-502-07 (One per COSAMS) – Printed A3
12.
2 x Software User Manual (One per COSAMS)
13.
2 x test Certificate/statement of Conformity (One per COSAMS)
14.
2 x Data Download Tool (Analox USB Stick) (One per COSAMS)
15.
2 x Trimming Tool (One per COSAMS)
Table 3:
System checklist
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Transport and storage considerations
To avoid equipment damage when storing or transporting a COSAMS unit it must
always be packed in its Pelican 1630 transport case.
CAUTION:
WHEN STORING OR TRANSPORTING A COSAMS UNIT IT MUST
ALWAYS BE PACKED IN ITS PELICAN 1630 TRANSPORT CASE.
CAUTION:
PRIOR TO POWERING UP THE INSTRUMENT, IT SHOULD ALWAYS
BE ALLOWED TO RETURN TO ITS OPERATING TEMPERATURE
RANGE AND ANY CONDENSATE THAT MAY HAVE FORMED MUST BE
ALLOWED TO EVAPORATE.
NOTE:
DETAILS OF PERMISSIBLE STORAGE TEMPERATURE, HUMIDITY
AND PRESSURE RANGES CAN BE FOUND IN SECTION,
ENVIRONMENTAL SPECIFICATIONS.
NOTE:
THE COSAMS WILL REQUIRE CALIBRATION AFTER TRANSPORT OR
STORAGE. IF UNITS ARE STORED FOR LONG PERIODS, THE
FILTERS AND CATALYSTS MAY/ WILL NEED TO BE CHANGED
PRIOR TO USE.
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5
Installation details
5.1
Overview
Approved
The COSAMS electronics are housed in a custom-made cabinet fabricated from 5000
series aluminium. External surfaces are painted with RAL7001 (silver grey) epoxy paint
to DTD5555A (MIL-22750F) with low-profile spatter finish.
The cabinet has two lugs per side for direct-mounting to a bulkhead and blanked-off
drillings in the rear and lower face to allow mounting on shock-isolators.
The enclosure achieves a minimum ingress protection of IP44.
Fig 3: COSAMS overview
Access is required from the left hand side for the electrical connections:



power input (1)
4-20mA signal output (2)
earth stud for equipotential bonding to the submarine hull (4)
Two waterproof fuse holders are also accessed from the left hand side (3).
Gas sample is drawn through an inlet (5) in the cabinet’s base and exhausts out of the
right hand side (6). A water-proof breather port (7) is also mounted on the right hand
side to ensure that cabinet internal pressure tracks submarine compartment pressure.
Push-fit sinters are supplied with the COSAMS and one should be fitted in both the inlet
and exhaust ports to pre-filter the sample and guard against water entry in the event of
splashing.
Access to the cabinet base and right-hand side will be required to maintain the prefilters and also when applying calibration gas to the COSAMS.
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5.1.1
Approved
Tools/consumables required for installation
Installation of the hardware is possible using standard hand tools (i.e. spanners/socket
set, screwdrivers, hex keys, soldering iron, etc.); no special tools or consumables are
required although a long blade PZ1 screwdriver (Approx 200mm blade length) is
required for the pump replacement.
Upon installation, the system should be calibrated according to section 8.
5.2
Mechanical installation
5.2.1
Mounting COSAMS in the accommodation area (forward compartment)
The COSAMS in the forward compartment must be installed using the shock isolators
provided with the system. The COSAMS is designed to sit on an appropriate supporting
structure and be secured to a bulkhead at the rear, as indicated in Fig 4:
Fig 4: Mounting arrangement in the accommodation area
Procedure
[1]
Remove the COSAMS internal baseplate assembly, as described in section
12.3.4, to gain access to the rear shock isolator mounting points.
[2]
Remove the two M12 x 25mm bolts/washers/nuts that penetrate the rear of
the cabinet and the two that penetrate the lower face of the cabinet to
reveal the shock isolator mounting holes.
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Fig 5: Shock isolator mounting points
[3]
Fit an M12 x 50mm bolt and flat washer in two of the shock isolators; the
head of the bolt should be ‘within’ the shock isolator and the shank
protruding out-over.
Fig 6: Shock isolator preparation
[4]
Fix the shock isolators to the submarine structure using M8 hardware – two
bolts are required for each of the four isolators. The two isolators fitted with
the M12 x 50 bolts should be mounted on the vertical bulkhead and those
without should be mounted on the horizontal supporting structure.
Relative positions of shock isolators mounting holes are indicated in Fig 7:
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[5]
Sit the COSAMS cabinet on the lower shock isolators, guide on to the bolt
shanks protruding from the upper isolators and fix to the upper isolators
using an M12 flat washer/spring washer/nut on each. As each isolator is
pulled in to the back of the COSAMS cabinet, the ‘head’ should seat in a
shallow recess, preventing rotation as the nuts are tightened.
[6]
Fix to the lower isolators with M12 x 25mm bolts/spring washers/flat
washers, fitting from within the cabinet and screwing in to the head of the
isolator.
[7]
Re-install the internal baseplate (refer to section 12.3.4).
CAUTION: THERE MUST BE A MINIMUM OF 40MM BETWEEN THE COSAMS
AND ANY NEIGHBOURING EQUIPMENT TO ALLOW UNINHIBITED
MOVEMENT OF THE SYSTEM IN THE EVENT OF THE SUBMARINE BEING
SUBJECT TO SHOCK.
Fig 7: Relative positions of COSAMS shock isolator mounting points and
suggested cut-out to provide clearance around electrical connectors
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Approved
Mounting COSAMS in the engine room (aft compartment).
The bulkhead supporting the COSAMS in the aft compartment is shockisolated and therefore the COSAMS should be mounted directly to it.
Secondary shock mounts should NOT be used as this may result in
amplification of the magnitude of any transmitted shock.
Fig 8: Mounting arrangement in the engine room
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M8 hardware should be used to securely bolt the COSAMS to the bulkhead
using the two mounting lugs protruding from either side; the relative
positions of the rectangularly arranged mounting holes (330 x 369mm
centres) are indicated in Fig 9:
Fig 9: Relative positions of COSAMS mounting holes in engine room
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5.3
Approved
Electrical installation
Three external electrical connections are required to the COSAMS:



power input
signal output
equipotential bonding strap
CAUTION:
ALL CONNECTIONS TO THE COSAMS MUST HAVE SUFFICIENT
‘SLACK’ TO ALLOW FOR AT LEAST 40MM MOVEMENT OF THE
CABINET IN ANY DIRECTION IN RESPONSE TO MECHANICAL
SHOCK.
The COSAMS cabinet has a 3-way, male, chassis-mounted plug for connection to an 85264Vac, 47-63Hz supply; maximum power consumption is 90W. A mating connector (3way, female, cable-mounting socket) is supplied with COSAMS.
A 3-way, female, chassis-mounted socket provides connection to the 4-20mA output
signal and a mating connector (3-way, male, cable-mounting plug) is supplied with
COSAMS.
5.3.1
Cable identification
The required cables to connect to COSAMS are shown below:
Power input
(115V, 60Hz)
Signal output
(4-20mA)
Table 4:
Engine room
Accommodati
on area
Cable #
3945
3946
Cable type
LMGSGO
LMGSGO
Cable size
2x1.5mm2
2x1.5mm2
Cable #
4765
4775
Cable type
EPD74918
EPD74918
Cable size
3x1.5mm2
3x1.5mm2
Cable identification
Cables are to be terminated as follows:
Connector description
Manufacturer’s part
number
Power input (115V, 60Hz)
VG95234/MIL-STD-5015C 3way cable female socket, 90°
ITT Cannon CB8U14S-7SS
Signal output (4-20mA)
VG95234/MIL-STD-5015C 3way cable male plug, 90°
ITT Cannon CB8U14S-7PS
Table 5:
Connector details
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Power input (115V,
60Hz)
Signal output (420mA)
5.3.2
Approved
Pin no.
Function
Cable core
1
L1
Blue
2
L2
Black
3 [refer to the
CAUTION below]
Earth
Not connected
Body
Earth
Screen
1
Signal +
Red
2
Signal -
Black
3
Not connected
Not connected
Body
Earth
Screen
Table 6:
Connector pin-out
CAUTION:
NO CONNECTION IS TO BE MADE TO PIN 3 OF THE CABLE
MOUNTED POWER CONNECTOR. PIN 3 OF THE COSAMS CABINETMOUNTED PLUG IS CONNECTED TO THE CABINET BODY IN ORDER
TO MAKE PROTECTIVE EARTH CONNECTION DURING FACTORY
SET UP AND TESTING.
Signal output
An Analox SDA output module controls a 4-20mA analogue signal proportional to the
perceived CO concentration over the range 0-200ppm. The module is configured to
operate in active mode and compliance is maintained for loop resistances up to 500Ω.
The analogue output is set to ~2mA during warm-up and in the case of a fault condition
being detected.
During the course of an auto-zero operation the 4-20mA output is maintained at a
value corresponding to the CO measurement recorded immediately prior to initiating
the auto-zero.
5.3.3
Equipotential bonding strap
A suitable flexible bonding strap must be attached to the COSAMS M8 earth bonding
stud. This will be the means of achieving HF bonding according to MIL STD 1310.
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Technical description
Fig 10: shows the COSAMS pneumatic arrangement and the internal electrical
arrangement.
Fig 10:
6.1
COSAMS internal pneumatic arrangement
Gas sampling
Sample gas is drawn in to the COSAMS through a push-in pre-filter in the underside of
the cabinet and then passes through an internal particulate filter.
After filtering, the sample flows through a solenoid valve which is energised periodically
to temporarily divert the sample through an extra loop of pipework. This extension to
the gas path incorporates a canister containing a catalyst which removes any CO
present in the sample stream, allowing the COSAMS to trim out any baseline signal
drift.
The sample pump is downstream of the solenoid valve/catalyst and the output from the
pump passes through an orifice restrictor to limit the rate of gas flow through the
sensor. A pressure switch monitors the pressure drop across the restrictor and an
absence of pressure drop is interpreted as a lack of sample flow.
Gas exits the sensor’s optical bench and exhausts through the outlet on the right-handside of the COSAMS cabinet.
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Fig 11:
COSAMS internal electrical arrangement
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6.2
Power supply
The COSAMS is powered from the boat’s 115V, 60Hz AC supply. The screen of the
incoming power cable is earthed at the supply end and connected to the shell of the
cable connector, providing 360 degree EMC protection.
It is expected that the electrical supply will be floating with respect to the submarine
hull, therefore both inputs (L1 and L2) are fused. Fuses F1 & F2 are housed in
externally-accessed, waterproof fuse holders mounted on the left-hand side of the
COSAMS cabinet.
Power filtering is performed by a general purpose EMI filter for improved EMC
performance. It should be noted that the filter has a 4.7nF capacitor between each line
and ground; this level of capacitance to the submarine hull is permissible under
MIL_STD-461F, which imposes a 100nF limit.
The filtered supply then connects to a universal input (85 to 264V AC) isolated power
supply unit (PSU) which generates a 24V DC supply to power the instrument. The PSU
is rated for 70W continuous output; actual DC power consumption is typically 40W with
a 55W maximum. Isolation in excess of 500V AC for 60s is provided from input to
output, input to case (earth) and output to case (earth).
6.3
Power distribution
The internally generated 24V DC supply is distributed to the following items:




6.4
CO sensor
Interface PCB
SDA operator console
Solenoid valve circuit for auto-zero calibration (via SDA output module relay
contacts)
CO sensor
The CO sensor measures CO concentration using the gas filter correlation (GFC)
technique, making use of the infra-red absorption properties of CO. This technique is
particularly well-suited to the submarine application as it yields no response to
hydrogen (which produces false-positive readings from electrochemical sensors) and
has negligible cross-sensitivity to water vapour (unlike standard non-dispersive infrared absorption sensors).
The CO sensor sub-assembly is a 24V DC-powered device generating a non-linear DC
voltage output related to the concentration of CO in its optical bench. This output
voltage is fed in to the interface PCB where signal processing takes place.
CO sensor output is set to a nominal 0.8V in the absence of CO (0ppm) and 2.7V when
subjected to 200ppm CO at 20°C, 1000hPa.
The CO sensor also supplies the interface PCB with a ‘status’ output, indicating whether
the sensor is operating normally or if an internal fault has been detected.
6.5
Interface PCB
The interface PCB measures the temperature and barometric pressure within the
COSAMS cabinet and applies appropriate compensations to the CO sensor signal prior
to calculating the CO concentration in the sample gas stream and reporting to the SDA
operator console via an RS485 link (the 5-way connector plugged in to the SDA’s
Sensor socket).
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The interface PCB monitors numerous operating parameters, including gas flow and the
CO sensor’s Status line, and reports any fault conditions to the SDA operator console.
The interface PCB also controls timing of the auto-zero function, directing the SDA
operator console to energise the solenoid valve when required, and checks the outcome
of the operation for plausibility. Other calibration adjustments are performed as
directed by the SDA operator console. All sensor calibration data is stored within the
interface PCB.
Power to the COSAMS gas sample pump is supplied by the interface PCB’s internal 5V
rail.
6.6
SDA operator console
The SDA is the operator console, or user interface, for the COSAMS.
The SDA’s LCD shows the interface PCB-derived CO measurement and indicates the
system status by the colour of left-hand corner of the display:
Colour
Status
Green
OK
Yellow
Fault detected
Red
CO alarm threshold exceeded
The SDA operator console powers the SDA Output Module and communicates with it
over an RS485 link (the 5-way connector plugged in to the SDA’s Data socket), driving
the analogue output to a value commensurate with the measured CO concentration and
system status. The SDA also instructs the SDA Output Module to energise the solenoid
valve when the interface PCB indicates that an auto-zero is to be performed.
The SDA provides the operator with access to calibration functions and also to logged
data via the USB port on the rear of the console.
6.7
SDA output module
The Output Module is controlled by the SDA operator console which supplies 5V DC
power and sets the 4-20mA output signal level (refer to Section 5.3.2 for details on the
output signal).
The Output Module’s Normally Open relay is energised to operate the COSAMS solenoid
valve during the auto-zero operation.
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6.8
Electrical schematic
The internal wiring of the COSAMS is shown in drawing P0138-502-07, Fig 12: below.
Fig 12:
Internal wiring schematic
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7
Operating instructions
7.1
Controls
Fig 13: shows the COSAMS front panel:
Fig 13:
1
2
3
4
5
6
7.2
COSAMS front panel
LCD
Rotary encoder
Mute/Cancel pushbutton
Menu/Set pushbutton
Alarm set point controls
Calibration controls
Start-up
The COSAMS will automatically start up when power is supplied to it. Initially, the
COSAMS will display a splash screen as shown in Fig 15: below, for a few seconds:
Fig 14:
Start-up splash screen
After displaying the splash screen, the LCD will go blank for approximately 15 seconds
and then the ‘normal’ COSAMS operating screen will display.
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7.3
Warm-up
Fig 15:
Warm-up screen
Upon start-up, the CO sensor requires a period of up to 4 hours to ‘warm up’ and
achieve accurate readings. During this time, the screen will indicate that the sensor is
in warm-up mode, displaying a countdown to normal operation, and the CO reading will
be shown in grey text preceded by a “~” symbol (see Fig 15:), indicating that the value
is approximate and should be regarded with a degree of scepticism.
The analogue output is clamped to the fault level during warm up.
In the event of a brief interruption to the COSAMS power supply, the system will enter
a shortened warm-up period with duration being proportional to the time spent unpowered.
7.4
Normal operation
When the warm-up period has expired, the sensor reading will be shown in black text
and the analogue output signal will reflect the measured concentration of CO.
Key:
Fig 16:
1
Device identification label
2
Live sensor reading
3
Sensor type and display units
4
System status indicator
5
Alarm direction indicators
6
Alarm names
7
Alarm set-points
Main display overview
The live sensor reading is updated on the display approximately once per second. If no
valid sensor reading is currently available then the last ‘good’ sensor reading will be
displayed in grey text preceded by ‘~’.
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7.4.1
System status indicator
The system status indicator shows the current status of the COSAMS system.
In normal operation, i.e. the absence of any alarm or fault conditions, the system
status indicator will be green and read ‘OK’.
If any alarm condition has been identified then the system status indicator will turn red
and display the word ‘Alarm’.
If a system fault is detected then the status indicator will turn yellow and display the
word ‘Fault’.
The system indicator also uses icons to show system diagnostic information:
Fault. This icon indicates that a fault has been identified within the system. This
icon will be accompanied by a status code. See troubleshooting section for further
information on the specific condition. This icon will flash when a new fault condition
is identified and until the fault is acknowledged by pressing the mute button.
Processing. This animated icon indicates that the sensor module is performing
some internal function, such as calibration.
7.5
Menu
The main menu can be accessed from the main screen by pressing the Menu
pushbutton:
Fig 17:
The main menu
An arrow at the top or bottom of a menu indicates that there are more menu options
above or below those currently shown.
To select a menu item, rotate the encoder to highlight the required option and press
‘Set’ to select the highlighted item.
Selecting certain menu items will result in a sub-menu being displayed. Selecting the
back option from a sub-menu will return to the previous menu level.
The ‘Cancel’ pushbutton can be pressed at any time whilst using the menu to exit from
the menu.
The menu options available are listed in Table 7:
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Menu item
Purpose
Backlight…
Control the intensity of the display backlight
Auto-zero…
Instruct the COSAMS to perform an auto-zero calibration
Replace catalyst…
Instruct COSAMS that a new catalyst module has been fitted
Service…
Instruct the COSAMS that a service has been completed
Information
Access system information
Data logging
Access options to manage data log information
Exit
Exit from menu and return to normal operating screen
Table 7:
7.5.1
SDA operator console menu items
Adjusting the backlight
The brightness of the COSAMS display can be changed to suit the local lighting
conditions by adjusting the backlight intensity.
Selecting the ‘Backlight’ option from the main menu results in the ‘Set backlight’ submenu being displayed. Highlight the desired backlight intensity level (10 to 100%) and
press the Menu/Set pushbutton.
To exit from the sub-menu without changing the backlight intensity, either press the
Mute/Cancel pushbutton or select the ‘Back’ option to return to the main menu.
Fig 18:
The backlight sub-menu
CAUTION:
DUE TO THE NATURE OF THE DISPLAY TECHNOLOGY, THE
MAXIMUM INTENSITY OF THE DISPLAY WILL DEGRADE SLIGHTLY
OVER THE LIFESPAN OF THE PRODUCT. FOR NEW SYSTEMS IT IS
RECOMMENDED THAT THE BACKLIGHT IS SET TO AN INITIAL
INTENSITY LEVEL OF 60% OR LESS TO MAXIMISE THE LIFESPAN
OF THE DISPLAY.
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7.5.2
Auto-zero function
The auto-zero function is initiated automatically after the COSAMS warm-up period has
expired and then periodically thereafter to trim out any drift in the sensor’s baseline
output. The user may also manually initiate an auto-zero operation via the menu
option, allowing a zero calibration to be performed when a technician does not have
access to zero calibration gas.
During the auto-zero process, the solenoid valve is energised to divert flow through the
catalyst module, scrubbing the gas of any CO by oxidising to CO2. The COSAMS will not
monitor ambient CO concentration whilst engaged in the auto-zero so the CO reading
will be displayed in grey and preceded by the ‘~’ symbol; the 4-20mA signal level will
be maintained at the same level as immediately prior to starting the auto-zero.
Factory default timings for the auto-zero operation are:
Period between auto-zeroes:
Auto-zero duration:
Fig 19:
7.5.3
6 hours
3 minutes
Zeroing sensor indication
Replacing catalyst
If the COSAMS rejects an auto-zero result due to a suspected problem with the
catalyst, the ensuing fault announcement (see Table 8:) can be cleared by selecting the
Replace catalyst… option.
7.5.4
Resetting the service interval timer
After servicing the COSAMS, the service interval timer may be reset to 1 year by
selecting the Service… option.
7.5.5
COSAMS information
An information screen can be accessed to check the configuration of the system. From
the Main Menu, select the ‘Information’ option.
Fig 20:
COSAMS information screen
This screen shows the software version number, the instrument serial number, various
settings, and the time until a service is due.
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7.5.6
Data logging
The SDA unit logs measurement data over a 90-day period at 10-second intervals. The
following parameters are logged:
1.
2.
3.
4.
System status
Average CO reading over the last 10s period
Minimum CO reading during the last 10s period
Maximum CO reading during the last 10s period
When the log is full, i.e. 90 days of data has been collected, the oldest data is overwritten such that the log contains a continuous record of the preceding 90 days.
Downloading logged data
There are two ways of downloading logged data, one via the SDA Operator Console
(SOC) menu system and the other via a Data Download Tool (DDT) provided with the
COSAMS.
Logged data is available to the user via the USB port located on the rear of the SDA.
The data provides the following information:
Date
Time
Status
CO Units
CO Average
CO Max
CO Min
08/01/2014
12:44:16
OK
ppm
0
0
0
08/01/2014
12:44:26
OK
ppm
0
0
0
Fig 21:
Example of data logged by system
To download logged data using the SDA Operator Console (SOC):
[1]
Plug a USB flash drive into the USB port on the SDA (this is on the rear of the
enclosure door - see the photograph below):
[2]
Go to the SDA operator console on the front of the enclosure door.
[3]
Press the Menu/Set button, then scroll through the options using the rotary
encoder.
[4]
Press the Menu/Set button again to select the ‘Data logging’ Menu option.
[5]
Press the Menu/Set button again to select ‘Download data to USB...’ Data
will download to the USB flash drive, with one CSV file for each day of data.
When download is complete, the files can be imported directly to Microsoft
Excel or similar spreadsheet packages.
To delete logged data:
[1]
Press the Menu/Set button, then scroll through the options using the rotary
encoder.
[2]
Press the Menu/Set button again to select the ‘Data logging’ Menu option.
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[3]
Press the Menu/Set button again to select ‘Delete all data-logs’. All logged
data will be deleted.
To download logged data using the Data Download Tool (DDT) (Analox branded USB
stick):
[1]
When using the Data Download Tool the files stored on the COSAMS device
will not be affected.
[2]
Open the COSAMS enclosure using the supplied cabinet key
[3]
Locate the USB “TECH” port on the rear of the SDA Operator Console (SOC)
and fit the DDT
[4]
Locate and unplug the power supply cable in the back of the SOC designated
by idents 30 (black wire) and 29 (red wire). After a minimum period of 5
seconds reconnect the power supply cable in the back of the SOC.
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[5]
Check the SOC display shows the device splash screen. After a short period
the splash screen will go blank before the DDT Diagnostic & Fault Extractor
software starts.
[6]
This will automatically download the device datalogs, Once datalog
download is complete the device will start downloading diagnosis logs
[7]
Once datalogs finish the fault log download will start.
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[8]
Once all downloading is complete the Status will show as finished and
request the USB device to be removed.
[9]
Once the USB device is removed, close the COSAMS cabinet door and lock.
[10]
The SOC will automatically reboot and enter a reduced COSAMS warm up
period prior to normal operation mode.
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8
Calibration
CAUTION:
INCORRECT USE OF CALIBRATION GAS CAN ADVERSELY AFFECT
THE INSTRUMENT’S PERFORMANCE. ONLY TRAINED PERSONNEL
SHOULD ATTEMPT CALIBRATION.
It is intended that the COSAMS be calibrated immediately prior to a patrol or every 30
days to maintain accuracy. The auto-zero function, described in section 7.5.2,
maintains accuracy during the period of the patrol.
8.1
Zero and span calibration
Two gases are required to calibrate the COSAMS, zero gas (0ppm CO) and span gas (a
high concentration of CO in air balance), as detailed in section 12.2.
Zero gas calibration should be performed first, followed by span gas calibration.
NOTE:
THE COSAMS MONITORS THE AMBIENT AIR AT THE GAS INLET TO
THE INSTRUMENT, USING AN INTERNAL PUMP TO DRAW A GAS
SAMPLE THROUGH THE SENSOR.
Calibration gas may be connected to the sample inlet while calibrating, provided it is
controlled by a suitable regulator as described in section 8 and section 12.4.7.
Gas pressure at the inlet port must not exceed 500hPa (gauge pressure).
Do not obstruct the exhaust port.
8.1.1
8.1.2
Performing a zero calibration
[1]
Remove the push-fit pre-filter in the gas inlet and supply the COSAMS with
zero gas at a flow rate of 0.5 – 0.7 lpm via Ø6mm tubing.
[2]
Maintain the gas flow for approximately 3 minutes, by which time the
COSAMS CO reading should have reached a steady value.
[3]
Press and hold the Zero Calibrate pushbutton and press the Menu/Set
pushbutton to initiate the calibration. Releasing the Zero pushbutton before
pressing Menu/Set will abort the calibration and return the COSAMS to
normal operation.
[4]
The COSAMS will attempt a calibration, resulting in either a ‘Calibration OK’
or a ‘Calibration failed’ message as shown in Fig 22:
[5]
Press the Mute/Cancel button to clear any calibration messages that may
remain on-screen.
Performing a span calibration
[1]
Switch from zero gas flow to span gas flow and maintain 0.5 – 0.7 lpm flow
rate for approximately 3 minutes, by which time the sensor reading should
have reached a steady value.
[2]
Press and hold the Span Calibrate pushbutton; the calibration value entry
panel will be shown (Fig 22:) with the cal. gas CO concentration displayed in
blue.
[3]
Use the rotary encoder to adjust the value to the CO concentration in the
calibration gas.
[4]
Press the Menu/Set pushbutton to initiate the calibration. Releasing the
Span pushbutton before pressing Menu/Set will abort the calibration and
return the COSAMS to normal operation.
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[5]
The COSAMS will attempt a calibration, resulting in either a ‘Calibration OK’
or a ‘Calibration failed’ message as shown in Fig 22: below.
[6]
Press the Mute/Cancel button to clear any calibration messages that may
remain on-screen.
Fig 22:
Span adjustment
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9
Alarms
The COSAMS can provide two alarm indications, triggered on detection of a high level
(Hi) of CO and very high level (Hi Hi). COSAMS is supplied with these alarm thresholds
set at 999ppm CO, effectively disabling alarm annunciation. It is possible to bring the
alarms in to use by adjusting the alarm set points to within the COSAMS’ range of
measurement, as described in section 9.1.
Alarm annunciation is limited to visual indication on the SDA operator console: the
system status indicator will flash red and display ‘Alarm’, the measured CO
concentration will be displayed in red text and the relevant alarm set point will display
in red text. Audible alarm annunciation is inhibited.
The 4-20mA output signal is completely unaffected by alarm state.
9.1
Adjusting alarm set points
If desired, the user may adjust the set point(s) to within the CO measurement range,
thereby activating the alarm(s).
NOTE:
IF THE SDA OPERATOR CONSOLE IS USED TO ACTIVATE THE
ALARMS IN THE MANNER DESCRIBED BELOW THEN THE
TECHNICAL IN-SERVICE SUPPORT SOFTWARE DESCRIBED IN
SECTION 10 WILL BE REQUIRED TO RETURN THE SET POINTS
OUT-OF-RANGE; THE MAXIMUM SET POINT VALUE ACHIEVABLE
VIA THE OPERATOR CONSOLE IS 200PPM CO.
To adjust a set-point, press and hold the relevant alarm-adjust pushbutton - top button
for Hi Hi alarm, bottom button for Hi alarm. The alarm adjustment panel will be shown
at the bottom of the LCD, alongside the system status indicator. The panel shows the
name of the alarm to be adjusted and the current alarm set-point in yellow (Fig 23:).
Keep the alarm-adjust pushbutton depressed and use the rotary encoder to adjust the
set-point: turn clockwise to increase, anti-clockwise to decrease.
NOTE:
TO QUICKLY REDUCE THE ALARM SETTING FROM THE INITIAL
999PPM SETTING, SIMPLY ATTEMPT TO ADJUST THE SETPOINT
UPWARDS (CLOCKWISE). THE VALUE WILL THEN SNAP TO
200PPM, FROM WHERE IT CAN THEN BE ADJUSTED NORMALLY.
When the desired set value is reached, keep the alarm-adjust pushbutton depressed
and press the Menu/Set pushbutton to accept it; the value will turn green, indicating
confirmation of the new set point and the alarm-adjust push button can be released.
Fig 23:
Example of alarm set-point adjustment
NOTE:
RELEASING THE ALARM-ADJUST PUSHBUTTON PRIOR TO
CONFIRMATION WILL RETURN THE SET POINT TO ITS ORIGINAL
VALUE.
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9.2
Acknowledging alarms
COSAMS alarms are latching meaning that, once triggered, the alarm annunciation will
continue until acknowledged by an operator, even if the CO concentration returns to a
low level.
Alarms are acknowledged by pressing the Mute / Cancel pushbutton.
If the alarm condition no longer exists when the alarm is acknowledged then the LCD
will revert to its normal operating condition upon acknowledgement, otherwise, the
system status indicator will remain red but cease to flash, the CO will still be displayed
in red, as will the appropriate alarm set point. Only when the alarm condition has
cleared will the display revert to normal operation.
9.3
Clearing alarms and hysteresis
An alarm will always trigger immediately when the sensor reading exceeds an alarm set
point. However, to avoid nuisance re-triggering of alarms when a sensor reading is
fluctuating around an alarm set point, the CO level must drop a certain amount below
the set point before an acknowledged alarm will clear. This difference between the
alarm set point and the lower CO level at which an acknowledged alarm will clear is the
alarm’s hysteresis.
Fig 24:
Alarm hysteresis
The hysteresis applied to an alarm is calculated as a percentage of the set point value
with an upper limit imposed.
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10
Technical in-service support software
COSAMS SDA software is provided to allow the device to be configured using a USB
connection. The software is designed to run on Microsoft Windows®. Please refer to the
COSAMS Software Manual P0138-812 contained on the COSAMS Software CD.
The utilities on the CD are not required in normal use but may be of benefit in the event
of in-service support being required.
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11
Troubleshooting
11.1
Fault announcement
The COSAMS constantly monitors for fault conditions; any that are identified will trigger
a fault announcement.
The system status indicator will flash yellow, and the 4-20mA signal will be set to
~2mA.
Fault announcements can be acknowledged by pressing the Mute/Cancel button; the
system status indicator will cease to flash and analogue output will remain high until
the fault condition is rectified.
All fault announcements are latching; if an intermittent fault condition is identified and
subsequently clears (e.g. gas flow is temporarily interrupted), the fault announcement
will continue until it has been acknowledged.
Fig 25:
11.2
Fault indication (example of a flow fault)
Fault diagnosis
Information about the fault condition is displayed just below and to the left of the CO
reading, as shown in Fig 25:
In cases where a fault prevents a valid reading from being obtained from the sensor,
then the last good reading will be shown in grey, preceded by ‘~’.
11.3
Fault logging
All instances of fault conditions that are identified will be logged to the COSAMS‘s
diagnostics log (both the point at which the fault is identified and the point at which the
fault is cleared will be logged).
The diagnostics log can be downloaded using the COSAMS SDA software or the Data
Download Tool, see section 7.5.6.
Please refer to the COSAMS Software Manual P0138-812 contained on the COSAMS
Software CD for information on how to access this.
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Table 8: below shows a full list of fault messages together with a description of the
cause and suggested remedies.
Fault message
Cause
Solution
Sensor fault: OMF
Unable to establish
communications between SDA
and Output Module via RS485
communication link.
Check integrity of comms connections on SDA
and Output Module. If connections are
satisfactory but fault persists, replacing the
Output Module or the SDA Operator Console
may solve the problem.
Sensor fault: ACZ
The auto-zero calibration process
did not complete successfully:
Check calibration of sensor using zero gas
(section 12.4.7). If catalyst is OK, then this
should also result in a calibration fault. If
catalyst is the problem, then calibrate with zero
gas should succeed. To identify whether or not
the catalyst is the source of the problem, first
ensure that the switching solenoid is operating.
The solenoid valve is switched by a relay in the
Output Module, so ensure that power is
reaching the solenoid valve via the Output
Module relay.
- the sensor output has drifted
too far from its initial value or
- another fault condition, which
might prevent correct calibration,
was detected during the
procedure
If all OK, but auto-zero still fails, then replace
catalyst module.
Sensor fault: CAT
The auto-zero calibration did not
complete successfully, the
calculated adjustment required
has changed by an unacceptable
amount since the previous autozero.
Check operation of the solenoid valve.
Sensor fault: CRC
Code or data corruption within
the interface PCB.
Should the interface PCB need to be replaced,
contact Analox.
RNG or SRF
The sensor’s reading is outside of
acceptable range.
This problem can often be solved by a full
calibration of the sensor. If this problem
persists, contact Analox and provide a copy of
the data logs and fault logs.
Sensor fault: FLW
Defective flow switch or
insufficient gas flow caused by
any of:
Check pump is running – if it isn’t, check that
5V DC supply from the interface PCB is good.
Sensor Fault: ICF
If the valve is switching satisfactorily, replace
the catalyst module.
Reset the catalyst fault from the main menu as
detailed in section 12.3.2.
Check inlet, outlet pre-filters and internal filter
for line blockage.
Blocked inlet filter
Blocked outlet filter
Blocked internal filter
Defective pump
No electrical supply to pump
Internal pipework leak
Check pipework connections are good.
Check flow switch operation.
The interface has detected a low
level on its ‘GFC OK’ signal line.
Check integrity of the ‘GFC OK’ signal wiring.
Sensor comms
fault: SCF
Communications between SDA
and interface PCB have been
interrupted/lost.
Check integrity of comms connections on SDA
and interface PCB modules. If connections are
satisfactory but fault persists then contact
Analox.
Sensor fatal error:
Interface PCB has experienced a
fatal error.
Should the interface PCB need to be replaced,
contact Analox.
FTL
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If connection between the GFC sensor and
interface PCB is good then contact Analox.
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Fault message
Cause
Solution
Sensor fault: NFF
An unexpected non-fatal fault has
occurred.
Note the occurrence of the alarm and report to
Analox together with any information which
may be relevant. Acknowledge the fault and
attempt to continue operating.
Sensor Fault: PWR
The interface PCB’s internally
generated 5V DC is out of
specification.
Condition may be caused by faulty pump which
is powered by the interface PCB’s 5V DC rail.
Sensor range fault
The CO reading is below the
expected minimum value.
Recalibrate using SDA operator console. If fault
persists, perform a ‘coarse’ calibration, as
described in section 12.4.7. If this cannot be
achieved, contact Analox.
Sensor range fault:
SRF
The interface PCB has reported a
pressure reading falling outside
the expected range.
If the pressure is considered within the normal
range, then contact Analox.
Sensor fault: TMP
Unit is operating outside the
operating temperature range.
Check ambient temperature – if within the
COSAMS operating range then contact Analox.
Pressure: PRE
Pressure is outside the range of
the unit.
Note the occurrence of the alarm and report to
Analox together with any information which
may be relevant. Acknowledge the fault and
attempt to continue operating.
Initialisation: INT
System has not initialised
correctly
Note the occurrence of the alarm and report to
Analox together with any information which
may be relevant. Acknowledge the fault and
attempt to continue operating.
Noise: NSY
Outside of power supply unit‘s
operating range.
Check the power supply unit (PSU).
Flash memory is corrupt.
Note the occurrence of the alarm and report to
Analox together with any information which
may be relevant. Acknowledge the fault and
attempt to continue operating.
CRC error: CRC
Table 8:
If pump is OK the interface PCB may need
replacing; contact Analox.
Note the occurrence of the alarm and report to
Analox together with any information which
may be relevant. Acknowledge the fault and
attempt to continue operating.
Fault codes
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12
Maintenance
12.1
Spare parts
Table 9: shows spare parts available to order:
Item
Description
Analox part number
1
COSAMS instrument
COSAMS-NSM
2
Set of 4 shock mounts for accommodation area installation
2837-0032S
3
Shock mount fixing kit
2837-0032SFK
4
Power input connector (To be ordered with item 6)
2535-0114
5
Signal output connector (To be ordered with item 6)
2535-0115
6
Heatshrink boot
2535-0116
7
Enclosure locking key
2836-0032
8
USB lead
9300-1008
9
COSAMS software CD
P0138-907
10
User manual
P0138-810
11
Case breather
9456-1538
12
Power filter
2533-1010
13
Fuse holder
2532-0091
14
Fuse (pack of 10)
2531-7508/P
15
24V DC power supply
2822-0041
16
Sample pump kit (includes pump & mounting hardware)
DD1COSAMSPKMOD03
17
Solenoid valve
6000-0194
18
Flow switch
FS6202CV-1MCOSAMS
19
Analox COSAMS SDA operator console
SDAPCOSAMS
20
Analox SDA Output Module PCB Assembly
XK0-213-COSAMS
21
Gas inlet/outlet pre-filter
6000-0193
22
Catalyst assembly (internal)
P0138-603
23
Replacement internal filter element and O-ring (Pack of 10)
2533-1100
24
Infra-red source for GFC CO sensor
MGA-014
25
Door EMC Gasket (Supplied in 1 metre lengths)
2321-0117
26
COSAMS membrane switch label
P0138-407
27
Baseplate assembly including sensor
P0138-601/03
Table 9:
COSAMS spare parts list
Sundry minor fasteners and pneumatic items can also be supplied, if required. Please
contact Analox for further information.
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12.2
Special maintenance equipment
Besides common hand tools (screwdrivers, spanners, multi-meter, etc.), Analox
recommend that the following equipment is available for maintaining the system and
ensuring optimal performance:
Item
Description
1
Analox COSAMS software CD (supplied with system)
2
USB cable (supplied with system)
3
PC or laptop running Windows XP or later for use with Analox software (not supplied
by Analox)
4
Zero calibration gas: 20.9% oxygen in nitrogen recommended (to be sourced locally)
5
Span calibration gas: 150ppm CO in air/ N2 recommended (to be sourced locally)
6
Demand flow regulator required for calibration gas bottles; required flow rate is
approximately 0.6 lpm
7
Calibration gas hose (COSAMS gas inlet accepts 6mm outside diameter), 6mmOD x
4mmID Polyurethane tubing (For example Legris 1025U06 04)
Table 10:
Special maintenance equipment
Choice of calibration gas bottle will be subject to preference, being a compromise
between storage space requirements, portability and capacity/longevity.
Analox recommend that a fairly small bottle is chosen, allowing the gas to be carried on
board the submarine. For example, in the UK we would recommend the use of 110 litre
S-Can bottles (360mm long x Ø86mm, 1.55 litres water capacity, fill pressure of 68
bar).
A demand flow regulator, suitable for use with instruments that use a pump to draw a
sample should be used to deliver gas to the COSAMS. Flow rate will be in the region of
0.6 lpm.
150ppm CO in air is recommended for performing span calibration; this concentration
has been chosen to match that used for calibrating previous CO sensors. Any CO
concentration in the range 120 – 200ppm CO could be used, if required.
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12.3
Periodic maintenance
The Analox COSAMS has been designed to require minimal maintenance and minimal
spare parts inventory. Most elements of the system maintenance can be carried out by
Level 1 (on board maintenance personnel). Level 3 (contractor maintenance) should
only be required during either safety control maintenance or main overhaul.
The following have been identified as on-board maintenance tasks that are required to
ensure optimal operation, all tasks can be performed by submarine technical personnel:
Item
Task
Frequency
1
Check condition of inlet & outlet prefilters and internal filter. Replace as
necessary (12.3.1)
Initially per mission, but expected to be
relaxed to every 6 months
2
Sensor calibration
Pre-deployment or 6 monthly
3
Replacement of sample pump (12.3.5)
12 months
4
Replacement of auto-zero catalyst
module (12.3.2)
3 months
5
Check condition of cabinet breather port
and replace if necessary (12.3.3)
2 years
6
Replacement of GFC sensor’s infra-red
source (12.3.6)
2 years
7
Replacement of SDA operator module
7 years
8
Replacement of base plate assembly
7 years
Table 11:
On board maintenance tasks
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Fig 26:
COSAMS internal components (1)
Key
1
2
3
4
5
GFC CO sensor
Inlet pre-filter
COSAMS interface PCB
Auto-zero catalyst module
Internal particulate filter
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6
7
8
9
10
Sample Pump
Solenoid valve
Flow switch
SDA operator console
Rotary encoder
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Fig 27:
COSAMS internal components (2)
Key
1
2
3
4
5
Exhaust pre-filter
Breather port
Fuse holders
Power filter
Power supply unit (PSU)
WARNING:
MAINS VOLTAGE IS PRESENT WITHIN THE COSAMS CABINET
DISCONNECT THE POWER SUPPLY BEFORE PERFORMING
ANY MAINTENANCE WITHIN THE CABINET.
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12.3.1
Filter check and replacement
There are 3 filters requiring periodic replacement: the inlet and outlet pre-filters, which
are identical and the internal particulate filter.
12.3.1.1 Gas inlet and exhaust pre-filters
The pre-filters are push-fit fittings – remove by pushing the fitting’s collar against the
body of the fitting and withdrawing the pre-filter.
Gas inlet/exhaust pre-filter
Push collar against fitting body to release
grip on pre-filter
12.3.1.2 Internal filter element replacement
The internal filter is a cartridge-type, mounted on the baseplate assembly within the
COSAMS unit.
[1]
Unclip the left most cartridge from its bracket by pulling it away from the
baseplate.
[2]
Remove the tubing from the inlet (bottom) and tubing from the outlet
(top) by pushing the collar of the fitting toward the body of the cartridge to
release the grip on the elbow/tube.
[3]
Open the cartridge and remove the filter element by rotating the inlet end of
the cartridge anticlockwise to the open (‘O’) position.
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12.3.2
[4]
Pull out the inlet fitting and remove the filter element
[5]
Inspect the O-ring on the inlet fitting and replace with the new one supplied
with the replacement element, as required.
[6]
Insert the new filter element, re-assemble the cartridge and re-install in the
COSAMS.
Auto-zero catalyst replacement
The auto-zero catalyst is supplied in a filter canister; replacing the catalyst is simply a
matter of swapping out the old canister for the new. See Nanaucat MSDS in Appendix
at end of manual.
Follow steps [1] and [2] of the procedure for removing the internal particulate filter to
remove the old catalyst.
If the catalyst is being replaced as a result of the COSAMS reporting a catalyst fault
(Sensor fault: CAT):
[1]
Clear the fault by entering the SDA operator console main menu and select:
Replace catalyst… > CO sensor (1) > Yes
[2]
Manually initiate an auto-zero once the COSAMS warm-up period has
expired:
Auto-zero… > CO sensor (1)
12.3.3
Cabinet breather inspection/replacement
Inspect the cabinet’s breather port, externally mounted on the right-hand side of the
cabinet – if the central white, sintered section appears to be fouled then the breather
should be replaced.
Breather port in good condition
Replacement breather - ensure O-ring is
correctly seated prior to fitting
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The breather may be removed from the cabinet by unscrewing the plastic nut on the
rear. When installing a new breather, ensure that the O-ring is correctly seated in the
groove on the back face of the breather.
12.3.4
Removal and replacement of the baseplate assembly
It is necessary remove the COSAMS baseplate assembly to service/replace some
components and also to mount the cabinet on shock isolators.
12.3.4.1 Baseplate assembly removal
[1]
Disconnect the power input connector to isolate the COSAMS from the
supply.
[2]
Open the cabinet and disconnect the tubing at the gas inlet/exhaust ports.
(The gas inlet/exhaust ports are shown in the
photograph on the left, highlighted with arrows)
[3]
Unscrew the outer collar of the circular DC power connector 120° and unplug
the connector.
(The circular DC power connector is shown in the
photograph on the left, highlighted with an
arrow)
[4]
Unplug the SDA operator console power connector and the RS485
connections to the Interface PCB and Output Module PCB (marked SENS and
DATA, respectively).
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(The SDA operator console connectors are shown
in the photograph on the left, highlighted with an
arrow)
[5]
Remove the four sets of M8 nuts/spring washers/flat washers that retain
the baseplate.
(The M8 retaining nuts and washers are shown in
the drawing on the left, highlighted with arrows)
[6]
Withdraw the baseplate assembly from the cabinet, taking particular care
not to bump any parts of the GFC CO sensor.
12.3.4.2 Refitting the baseplate assembly
To refit the baseplate, ensure that the baseplate earth strap is located on the lower-left
mounting stud and then follow the removal instructions, section 12.3.4.1, in reverse
order.
CAUTION: ENSURE THE EARTH
STRAP SITS ON THE MOUNTING
STUD BEFORE REFITTING THE
BASEPLATE.
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12.3.5
Sample pump replacement
Replacing the sample pump requires removal of the baseplate assembly, as described
in section 12.3.4.
With the baseplate removed:
[1]
Disconnect the pump wiring from the terminal block (Wires 36 & 37) on the
rear of the baseplate, remove the three white low smoke cable ties securing
the pump wiring and feed through the oval grommet underneath the pump.
(The pump wiring terminal block is shown in the
photograph on the left)
[2]
Open the tube securing clips by pushing the clip open with a terminal driver
to loosen the teeth, then remove the tubing from the inlet (Left spigot) and
outlet (Right spigot).
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[3]
Pop the mount clip open around the pump body.
[4]
Remove the two M2.5 x 10mm Pozi Pan Screws, M2.5 spring washers and
M2.5 flat washers from the inside face of the pump bracket on the upright
using a long (200mm blade length) PZ1 screwdriver, access is via the gap
above the flow switch and below the GFC sensor.
Pump mount clip
M2.5 Pozi Pan Screws & washers
Installation of a new pump is the reverse of removal. Ensure that the tube clamps are
refitted over the pump spigots and tightened.
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12.3.6
Infra-red source replacement
Replacing the sensor’s infra-red source, located at the bottom end of the CO sensor,
requires removal of the baseplate assembly, as described in section 12.3.4. With the
baseplate removed:
[1]
Disconnect the source from the GFC sensor PCB connector (designated
CN50).
CAUTION:
THE SOURCE WIRING IS ROUTED AROUND THE HANDLE
STAND-OFF TO REDUCE THE RISK OF FOULING THE MOTOR
WHEN THE SENSOR IS OPERATING.
The infra-red source and PCB connections are
shown in the photograph in the left, highlighted
with arrows
[2]
Remove the two bolts and washers securing the source to the motor plate
(requires a 2mm hex key).
[3]
Fit the replacement source.
CAUTION:
THE SOURCE BOLT HOLES ARE OVER-SIZED ALLOWING A
HIGH DEGREE OF POSITIONAL VARIABILITY. CARE MUST
BE TAKEN TO ENSURE THAT THE SOURCE HOUSING DOES
NOT TOUCH THE SENSOR’S MOTOR AS THIS WILL CAUSE
THE SENSOR TO MALFUNCTION.
CAUTION: THE SOURCE HOUSING
MUST NOT FOUL ON THE MOTOR;
MAINTAIN A GAP OF AT LEAST
0.5MM.
[4]
Once the COSAMS has been re-assembled, powered-up and the warm-up
time has elapsed, calibrate the system (refer to section 12.4.7).
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12.4
Non-periodic maintenance
The following tasks are not part of the routine periodic maintenance but are detailed to
assist with repair of the COSAMS in the event of an unexpected component failure.
12.4.1
Replacing the power supply unit
Replacing the power supply unit (PSU) requires removal of the baseplate assembly, as
described in section 12.3.4.
With the baseplate removed:
[1]
Remove the 5 sets of M3 mounting hardware from the left-hand side of the
cabinet – the two on the left are M3 x 8mm and screw directly in to the PSU
itself, the three on the right are M3 x 16mm and hold the PSU supporting
bracket to the cabinet.
[2]
Unclip the terminal cover and disconnect all of the wiring connections.
[3]
Withdraw the power supply, and recover the PSU supporting bracket and
two mounting screws.
[4]
Fit the bracket to the new PSU – the screws should be treated with a
suitable thread-locking compound, e.g. Loctite 222, or a shake-proof washer
should be used to prevent loosening under vibration.
[5]
Wire up the new PSU as per electrical schematic in section 6.8 and also
printed copy included with instrument.
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[6]
Very loosely fasten the PSU to the cabinet using the two M3 x 8mm screws
(again, use either thread-locking compound or a shake-proof washer) to
allow alignment of the supporting bracket with its mounting holes. Fit the
PSU supporting brackets M3 x 16mm screws with M3 flat washers from the
outside of the cabinet and secure with the following hardware internally:
Mounting screw
Internal fittings/fasteners (in order of
fitting)
Top
cable clamp
M4 washer
M3 washer
M3 Nyloc nut
Middle
cable clamp
M4 washer
M3 washer
M3 Nyloc nut
Bottom
[7]
M3 Nyloc nut
Fully tighten all hardware.
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12.4.2
Solenoid valve replacement
Replacing the solenoid valve requires removal of the baseplate assembly, as described
in section 12.3.4.
With the baseplate removed:
[1]
Disconnect the solenoid valve electrical connector by unscrewing it from the
body of the solenoid valve.
[2]
Disconnect the pipework from the push-fit fittings, noting the relative
positions for re-assembly.
[3]
Undo the M3 mounting hardware from the underside of the baseplate to
remove the valve.
[4]
Recover the gas fittings from the base of the valve and install in the new
valve.
[5]
Orientate the gas ports and then mount the new valve on the baseplate.
[6]
Refit the pipework and electrical connector.
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12.4.3
Flow switch replacement
Replacing the flow switch requires removal of the baseplate assembly, as described in
section 12.3.4.
With the baseplate removed:
[1]
Remove the three white low smoke cable ties securing the flow switch
wiring and disconnect the flow switch wiring from the terminal rail on the
underside of the baseplate (Blue wire – 52) & interface PCB on the front of
the baseplate (40 & 41), remove the wiring by un-routing it on the underside
of the baseplate and feed through the oval grommet under the flow sensor.
[2]
Disconnect the flow switch pipework from the push fit elbows (Pump to ‘IN’,
‘OUT’ to GFC sensor inlet) on the flow switch.
[3]
Remove the M4 mounting hardware (Screw & Washer) to allow the flow
switch to be removed from the baseplate.
Above: Flow switch pipework and mounting hardware
Reverse steps [3] – [1] to install the new flow switch.
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12.4.4
Replacing the SDA Output Module PCB
Replacing the SDA Output Module PCB requires removal of the baseplate assembly, as
described in 12.3.4.
With the baseplate removed:
[1]
With the baseplate upside down, unplug the electrical connections from the
PCB.
[2]
Remove the PCB by unscrewing the three M2.5 Nyloc nuts and nylon
washers (This will also remove the insulating pillars underneath the PCB
from the baseplate).
[3]
Remove the insulated pillars from the PCB and refit to the baseplate.
[4]
Refit the PCB to the pillars and secure with the M2.5 Nylon washers and
Nyloc Nuts.
[5]
Refit the electrical connectors.
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12.4.5
Replacing SDA Operator Console membrane label
[1]
Loosen the grub screw (2mm hex key required) securing the rotary encoder
knob and remove the knob from the encoder shaft.
[2]
Remove the 2 encoder retaining nuts and pass the encoder back through the
panel.
[3]
Disconnect the ribbon cable, unfasten the shield tag and remove the
adhesive (used to prevent chafing of the wiring) from the slot in the cabinet
door.
[4]
Peel the membrane from the cabinet door and clean any remnants of
adhesive from the door.
[5]
Remove the protective film from the rear of the replacement label. Feed the
ribbon cable and shield tag through the slot in the cabinet door, align the
membrane with the LCD and encoder hole and affix the membrane to the
door.
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12.4.6
[6]
Connect the ribbon cable - the brown wire from the SDA should connect to
the ribbon track with the half circle in it.
[7]
Cut a small slot in the shield tag and fit over the stud on the rear top-right
corner of the SDA with one of the Nord lock washers above and one below.
[8]
Run a bead of glue/sealant, e.g. silicone sealant, along the cable slot to fix
the ribbon cable and shield tag in place and prevent chafing against the edge
of the slot.
[9]
Refit the rotary encoder and knob. Ensure that both nuts are used to mount
the encoder, this prevents damage occurring to the device in the event of
the knob being subject to an impact.
Replacing the SDA Operator Console
[1]
Disconnect the SDA electrical connections:
•
Unplug the ribbon cable connection to the membrane label and undo the
shield tag from the SDA’s upper earth stud.
•
Unplug the interface PCB, output module and power connectors.
•
Disconnect the earth wire attached to the lower earth stud.
•
Carefully peel away the adhesive around the ribbon cable attached to the
rotary encoder and unplug the encoder.
[2]
Undo the four nuts fastening the console to the mounting studs on the
cabinet door and remove the console.
[3]
Mount the new SDA console on to the mounting studs, fit the nuts and
washers and re-make all the electrical connections - the brown wire from
the SDA should connect to the ribbon track with the half circle in it.
[4]
Apply a bead of adhesive, e.g. silicone sealant, to the encoder/ribbon cable
connector joint to prevent accidental detachment.
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12.4.7
CO sensor calibration
There are two methods of CO sensor calibration:
a) ‘Fine’ calibration via the SDA operator console to maintain optimal performance as
the sensor output drifts slightly as the sensor ages. This procedure is described in
section 8.
b) ‘Coarse’ calibration is required when sensor output drift has become significant; the
GFC CO sensor’s potentiometers must be adjusted to return the sensor’s output to
the nominal levels expected by the interface PCB. ‘Coarse’ calibration should always
be followed by a ‘fine’ calibration.
The ‘coarse’ calibration procedure should be performed after servicing the COSAMS.
12.4.7.1
‘Coarse’ calibration procedure
‘Coarse’ calibration is best performed on a fully warmed-up system.
NOTE:
THE CO SENSOR IS SENSITIVE TO CHANGES IN TEMPERATURE;
FOR BEST RESULTS, TRY TO MINIMISE THE PERIODS WHEN THE
ENCLOSURE DOOR IS OPEN TO MAKE ADJUSTMENTS.
[1]
Connect a DVM (Digital Volt Meter) set to Volts dc to the red (+VE) & black
(-VE) test points located next to the ITT Cannon 7 way panel connector on
the baseplate using 4mm unshrouded test leads.
[2]
Remove central portion of lagging to gain access to the zero & span
potentiometers:
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[3]
Apply zero gas to the sensor, as described in the fine calibration procedure
(section 8).
[1]
Leave the gas to flow for approximately 3 minutes and then measure the CO
sensor output signal using the DVM across test points (Red +VE) and
(Black -VE) on the baseplate.
[2]
Adjust the GFC’s zero potentiometer using a trimming tool, located beneath
the optical bench, to achieve a sensor output voltage of 0.8 ± 0.05V.
[3]
Swap to span gas (Recommended at 150ppm CO in air), as described in the
fine calibration procedure (section 8).
[4]
Adjust the span potentiometer using a trimming tool to achieve a sensor
output voltage of 2.225 ± 0.05 V dc, this is dependent on using a 150ppm CO
in air span gas. If using a 200ppm CO in air span gas the output would be
~2.7 ± 0.05 V dc.
[5]
Repeat steps [2] through [6] until no further adjustment of the
potentiometers is required.
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[6]
Replace central portion of lagging.
[7]
Remove the test leads from the test points on the baseplate and shut the
cabinet door.
[8]
Allow the system temperature to stabilise for approximately 20 minutes and
then perform a fine calibration, according to section 8.
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13
Warranty
The first system delivered is under warranty for the 18 month period immediately
following the harbour acceptance test; subsequent systems that are installed
immediately upon supply will be under warranty for the 18 months immediately
following setting to work.
The warranty period for non-installed systems starts when the systems have been
received at the purchaser’s premises.
A 12 month warranty period applies to all new spare parts, provided that the purchaser
replaces relevant parts according to the replacement schedule advised in the technical
documentation delivered with the system.
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14
Fault reporting to Analox
In the event of a fault arising, the following table may be of use when reporting the
fault to Analox. Please complete all sections which are believed to be relevant to the
fault and return a copy to Analox, with a copy of the latest data log and fault log files contact details can be found on the front page of this manual.
Date
Customer details
Company/institution name
Customer contact
Address
Country
Telephone number
Mobile telephone number
Email address
Equipment details (where applicable)
COSAMS Cabinet serial no.
Cabinet MOD State
COSAMS baseplate serial no.
Baseplate MOD State
System Operating Voltage
Description of fault
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15
Specifications
15.1
Mechanical specifications
Nominal cabinet dimensions (mm):
479 x 280 x 175
h x w x d, exc. mounting lugs
Nominal system dimensions (mm):
600 x 360 x 200
h x w x d, exc. shock isolators
Nominal system dimensions (mm):
705 x 360 x 305
h x w x d, inc. shock isolators
15.2
15.3
Weight (kg, exc. shock isolators)
11
Cabinet material
Aluminium
Electrical specifications
Electrical supply
115V AC 60Hz
Max. power consumption
90W
Fuse rating (F1, F2)
20mm, 2.5A anti-surge
Signal output
4-20mA
EMC compliance
MIL-STD-461F
ESD compliance
EN 61000-4-2
Environmental specifications
Operating temperature range
0 to +55°C
Storage temperature
-40 to +70°C
Operating pressure range
800 to 1400 hPa
Extended pressure range1
600 to 800 hPa
Storage/transport pressure range
300 to 1400 hPa
Operating humidity range
0 to 80 %RH
Extended humidity range (up to 1 hr)
80 to 100 %RH
Storage humidity range
0 to 80 %RH (temporary max. 100 %RH)
Max. roll angle (constant)2
15°
Max. roll angle (temporary)
45°
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Max. pitch angle (constant)2
10°
Max. pitch angle (temporary)
30°
Shock
Tested at 22g, 20ms (half sine) without shock
isolation
Vibration
NATO STANAG 4138
Degraded performance is permissible over the pressure range 600-800hPa.
The system shall operate at any legal combination of roll & pitch angles and
continue to satisfy the specified accuracy requirement.
1
2
15.4
Performance specifications
CO measuring range
0 – 200 ppm
Repeatability, measured at RTP
± (1 ppm CO + 1 display count)
Accuracy across normal operating
environmental envelope
±5% full scale (equivalent to ± 10 ppm)
Zero drift
±1 ppm CO / day
Cross-sensitivity to hydrogen
2 %vol H2 < 1ppm CO
Cross sensitivity to carbon dioxide
5%vol CO2 < 1ppm CO
Response time
T90 < 60s
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16
Disposal
16.1
WEEE statement
According to WEEE regulation this electronic product
cannot be placed in household waste bins. Please
check local regulations for information on the
disposal of electronic products in your area.
Analox will provide a disposal service if this is
beneficial to the customer. Analox are registered for
the disposal of WEEE in the UK through the
Environment Agency (2013 Registration number
WEE/KE0043SY).
16.2
Catalyst disposal
Dispose of contents/container in accordance with applicable local regulations.
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17
Declaration of Conformity
Declaration number:
Manufacturer‘s name:
Manufacturer‘s address:
P0138-990-01
Analox Military Systems Limited
15 Ellerbeck Court
Stokesley Business Park
Stokesley
North Yorkshire
TS9 5PT
It is declared that the following product:
Product name:
Product code:
Conforms to all applicable requirements of:
COSAMS
P0138
MIL-STD-461F
BS EN 61000-4-2,
BV0430/85 (by calculation)
BV0430/73
NATO STANAG 4138
Signed on behalf of:
Date:
Analox Military Systems Limited
22/04/15
Signed:
Name:
Position:
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Mark Lewis
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Appendix - Nanaucat safety data sheet
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