New Cosmos Electric KD-12 Instruction Manual
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New Cosmos Electric KD-12 Instruction Manual

Diffusion type gas detector
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Diffusion type Gas Detector
Model KD-12
Instruction Manual
Keep this instruction manual where it is readily accessible.
Thoroughly read this instruction manual before using the equipment so it can be used
safely and correctly.
This manual provides information concerning standard specifications. If the specifications
of your model are nonstandard, refer to the delivery specifications.
New Cosmos Electric Co., Ltd.
Instruction Manual No.
GAE-048-00
September 2013

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  • Page 1 Thoroughly read this instruction manual before using the equipment so it can be used safely and correctly. This manual provides information concerning standard specifications. If the specifications of your model are nonstandard, refer to the delivery specifications. New Cosmos Electric Co., Ltd. Instruction Manual No. GAE-048-00 September 2013...
  • Page 2 • • • • Nomenclature • • • • Replacement of Sensor Unit See pages 4 to 6. See pages 29 and 30. • • • • Wiring and Connecting • • • • Display and Operation in Methods Each Mode See pages 11 to 15.

  • Page 3: Table Of Contents

    Table of Contents Introduction ........................1 Precautions........................2 Contents of Package ....................3 External Dimensions and Nomenclature..............4 4-1. Main Unit ........................4 4-2. Display and Control Blocks..................5 4-3. Terminal Block......................6 Installation........................7 5-1. Installation Method....................7 5-2. Examples of Installation Positions .................

  • Page 4: Introduction

    1. Introduction • Thank you for purchasing the KD-12 Diffusion type Gas Detector. • In order to ensure the correct and safe operation of this product, be sure to read this manual before use. • This product detects combustible gas, and CO2. The product detects gas leakage at an early stage in industrial facilities (e.g., gas production plants and depots, chemical plants,...

  • Page 5: Precautions

    Depth of engagement ..10.86mm Threads engagement The dimensions of flameproof joint between casing and casing cover of KD-12 flameproof housing are exceeding the minimum requirements stated EN/IEC60079-1. Please contact the manufacturer for inspection, repair and/or adjustments of this flameproof.

  • Page 6: Contents Of Package

    Note: 1. A hexagon wrench, Instruction Manual, and MJ-1 Magnetic Stick are provided for each order. 2. The optional items are for use only with KD-12. WARNING Do not use the magnetic stick for any purposes other than the operation of this product.

  • Page 7: External Dimensions And Nomenclature

    4. External Dimensions and Nomenclature 4-1. Main Unit Number Name Description Casing cover Casing Sensor unit Incorporates a gas sensor. Ground terminal Used when grounding the frame. State display Indicates the power supply state (green), alarm state (red), and indicator trouble state (yellow).

  • Page 8: Display And Control Blocks

    4-2. Display and Control Blocks Magnetic switches (Insert the magnetic stick to operate the magnetic switches.) Number Name Description Makes adjustments and settings or cancels the operation of MODE switch the product. ENTER switch Enters settings or completes the control of the product. Makes adjustments and settings or increases set values and ▲switch other values.

  • Page 9: Terminal Block

    4-3. Terminal Block 24V(+) POWER － 4～20mA Signal ＋ Ground Clamp terminal Lever Sensor connector O-ring Number Name Description 24 V (+) Power supply voltage (positive) Power supply voltage (-) and analog signal (negative) common Signal 4- to 20-mA (+) analog signal External contact Ground terminal Used to ground the frame.

  • Page 10: Installation

    Unused apertures shall be closed with suitable ATEX certified blanking elements. Fastener type M5 x 16 shall have a yield stress factor of min. 450 N/mm2. The dimensions of flameproof joint between casing and casing cover of KD-12 flameproof housing...
  • Page 11 CAUTION Be careful not to damage the gas detector when installing it. Otherwise, the explosion-proof performance of the gas detector will be lost. Do not install the product in the following places. - Places where the ambient temperature exceeds the operating temperature range (−10°C to 50°C).
  • Page 12 • Mount the main unit to the wall with the M5 screws that are provided with the product. Be sure to install the protective cover (optional) when mounting the main unit outdoors. Mount the main unit with a 2B pole mounting bracket (optional) when mounting the main unit to a 2B pole.

  • Page 13: Examples Of Installation Positions

    5-2. Examples of Installation Positions • Install the product in places where gas easily accumulates. Places where gas easily accumulates. Gas detector Roof fan Entrances and windows (Exhaust port) (Suction and exhaust ports) Entrance Gas detector (Suction port) mounting position Plan view Side view Example of Installation Position...

  • Page 14: Mounting Of Optional Items

    5-3. Mounting of Optional items • Protective Cover Horizontal Type (KW-41) Vertical Type (KW-42) CAUTION Secure the casing cover with M3 screws if strong winds are expected. • 2B Pole Mounting Bracket...

  • Page 15: Wiring Method

    6. Wiring Method 6-1. Wiring Work • Be sure to provide explosion-proof wiring if the product is to be used in a hazardous area. WARNING The cable entry device and blanking elements shall be of ATEX certified in type of explosion protection flameproof enclosure ‘’d’’, suitable for the condition of use and correctly installed.

  • Page 16: Wiring And Connection

    6-2. Wiring and Connection WARNING Before opening the casing cover of the gas detector, be sure to turn off the product and all devices (e.g., indicator unit and signal converter) connected to the product. If the power is turned ON, the power supply may become a source of ignition. Be sure to ground the product to prevent electric shocks.
  • Page 17 Not grounded terminals Grounded System Configuration Example Single detector connected Multiple detectors monitored to indicator unit together Detector Detector Indicator unit KD-12 Security management system KD-12 KD-12 VISION S-500 KD-12 Comprehensive gas detection/alarm system KD-12 For details, refer to the Instruction Manual of each device.
  • Page 18 6-2. Wiring and Connection (Continued) Typical Connection Procedure Prepare a power supply that can provide 24 V. (Do not turn on the power supply before wiring the main unit.) Loosen the hexagon socket bolts on the four corners of the main unit using the provided hexagon wrench with a nominal diameter of 4 mm, and open the casing cover of the main unit.

  • Page 19: Precautions Before Use

    7. Precautions before Use CAUTION Before turning ON any of the devices (e.g., indicator unit, signal converter) connected to the product, recheck that all of the connections are correct. Make sure that the gas detector and indicator unit or signal converter, in particular, are connected properly. In Case of Gas Leakage DANGER Without panicking, check that there is no fire around the product.

  • Page 20: Display At Start-Up (Initial Delay)

    8. Display at Start-up (Initial Delay) CAUTION Check that there is no gas around the product before starting the product. If the sensor output is not stable, the external contact point may operate after the initial delay. Release the interlock of the external equipment if necessary. During the initial delay, the analog signal fixed at 4 mA will be output and the external contact will not operate.

  • Page 21: Display And Operation In Each Mode

    9. Display and Operation in Each Mode In excess of alarm set value Maintenance mode At start-up Gas monitor Test mode Gas monitor (Initial delay) mode Test mode mode Green lamp Red lamp Red lamp lamp Green flashes flashes flashes Green flashes lamp is...

  • Page 22: Trouble Alarm

    10. Trouble Alarm • The product has a self-inspection function, and the trouble alarm will operate if a problem occurs. • The product will inform the user of the problem details with the display shown in the following table when the trouble alarm operates. •...

  • Page 23: Maintenance Check And Operation Method

    11. Maintenance Check and Operation Method 11-1. Daily Inspection and Periodical Inspection • Daily inspections are conducted by the user, while periodical inspections are conducted by your local representative. Frequency Check item Contents of inspection • The status of lamp (green POWER indicator) is lit.

  • Page 24: Preparing Calibration Gas

    11-2. Preparing Calibration Gas • Calibration gas is used for actual gas inspection. • The following example shows how to prepare 2.00 vol% (40%LEL) Methane as a reference gas. With a standard gas cylinder Gas bag 2.00vol% Methane air balance...
  • Page 25 11-2. Preparing Calibration Gas (Continued) With no calibration gas cylinder • Use the Gas Calibration Kit (optional) and a pure gas cylinder of methane at 99 vol% or more, and dilute the methane with air to produce 2.00 vol% (40%LEL) calibration gas.

  • Page 26: Calibration Method

    11-3. Calibration Method Maintenance Mode CAUTION While in maintenance mode, the external contact does not operate when the concentration of gas reaches or exceeds the alarm set value. The product in maintenance mode maintains the current status while the display shows [ This mode is canceled by repeating the same operation(1 to 4), turning the product OFF, or waiting 8 hours.

  • Page 27: Zero Adjustment

    Zero Adjustment • The external contact may operate. Therefore, set the product to maintenance mode if needed. MEMO Conduct the zero adjustment in a place where there is no ambient gas. While in gas monitor mode, press the MODE switch of the main unit first. Then press the UP switch with the magnetic stick within approximately 2 seconds.
  • Page 28 Span Fine-tuning MEMO Be sure to conduct the zero adjustment before performing span fine-tuning. CAUTION The external contact may operate during span fine-tuning. Set the product to maintenance mode or release the interlocks of the external devices if needed before performing span fine-tuning.

  • Page 29: Span Rough Adjustment

    Span Rough Adjustment • Perform span rough adjustment if is displayed. CAUTION The external contact may operate during span rough adjustment. Before performing span rough adjustment, set the product to maintenance mode or release the interlocks of the external devices if needed. Only your local representative’s maintenance service members or personnel who have completed a maintenance seminar can perform span rough adjustment.

  • Page 30: Full-Scale And Alarm Set Value Display

    Full-scale and Alarm Set Value Display • The full-scale and alarm set values are only displayed. They cannot be changed. While in gas monitor mode, press the MODE switch of the main unit first. Then press the UP switch with the magnetic stick within approximately 2 seconds. The main unit displays first, and displays (The product is ready to work but nothing has been operated.)

  • Page 31: Test Mode

    Test Mode • Test values are adjusted and used for tests in this mode. CAUTION The external contact may operate while the product is in test mode. Before setting the product to test mode, set the product to maintenance mode or release the interlocks of the external devices if needed.

  • Page 32: Replacement Of Sensor Unit

    If the sensor and the detector are incorrectly connected, the detector cannot detect gas. The dimensions of flameproof joint between casing and casing cover of KD-12 flameproof housing are exceeding the minimum requirements stated EN/IEC60079-1. Please contact the manufacturer for inspection, repair and/or adjustments of this flameproof.
  • Page 33 11-4. Replacement sensor unit (Continued) Turn OFF the power supply connected to the product. Rotate the sensor casing in the direction of the arrow and remove it. Pull down and remove the sensor as shown in the photo below. (2) Rotate the sensor casing (3) Pull down the sensor Insert the sensor to the main body while checking the positions of the pins and the holes.

  • Page 34: Troubleshooting

    12. Troubleshooting • Before requesting repairs, refer to the following table. Consult your New Cosmos representative if the product does not return to normal after taking the corresponding remedies shown below or if the defective condition is not found in the table. •...

  • Page 35: Specifications

    II 2 G Ex d IIC T5 Gb) EMC : EN61000-6-4:2001, EN50270:2006 - Type 2 Performance testing : The measuring function of the KD-12 gas detector for explosion protection, according to Annex II clause 1.5.5, 1.5.6 and 1.5.7 of the Directive 94/9/EC, is not covered in this certificate.

  • Page 36: Markings Of Explosion-Proof

    Power supply 24VDC (18 to 30 VDC) Power consumption 3W max. Size 158 (W) x 120 (H) x 68 (D) mm (excluding protruding parts) Weight Approx. 1.3kg Mounting method Wall mounting The above specifications are subject to change without notice. If your specifications are nonstandard, refer to the delivery specifications.

  • Page 37: Warranty

    15. Warranty New Cosmos Electric Company Limited (hereafter referred to as “New Cosmos”) offers the following as the sole and exclusive limited warranty available to the Customer. This warranty is in lieu of, and the Customer waives, all other warranties of any kind or nature, expressed or implied, including without limitation any warranty for merchantability or fitness for a particular purpose.

  • Page 38: Glossary

    17. Glossary Indicator / Alarm unit: A unit that receives signals from the gas detector and indicates gas concentration and alarms. Detector: A unit that detects gas concentration and converts it to electric signals. Backup power source device: A device that supplies power to the gas detector, indicator / alarm unit in order to maintain its performance during a power failure.
  • Page 39 Calibration gas: Gas used to calibrate scales of the equipment. Peak hold: A function to constantly update and hold the peak value of input signals. Hazardous area: An area in a plant or facility with a hazardous atmosphere where explosive gases may mix with air and explode or start a fire.
  • Page 40 Revision GAE-048-00 September 2013 Additional copies of this Instruction Manual are available. Contact the following address for ordering information. Distributor: Manufacturer: New Cosmos Electric Co., Ltd. 2-5-4 Mitsuya-naka Yodogawa-ku Osaka 532-0036, Japan Phone 81-6-6309-1505 Fax 81-6-6308-0371 Email e-info@new-cosmos.co.jp http://www.new-cosmos.co.jp New Cosmos Electric Co., Ltd.

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