Cosa 9610 Installation, Operation And Maintenance Manual
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Cosa 9610 Installation, Operation And Maintenance Manual

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™
INSTALLATION, OPERATION
AND
MAINTENANCE MANUAL
COSA 9610™
Version: 1.4.6
Revision date: Nov 9
th
, 2021
CAL.01.D.9826
2 |
P a g e

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  • Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ INSTALLATION, OPERATION MAINTENANCE MANUAL COSA 9610™ Version: 1.4.6 Revision date: Nov 9 , 2021 CAL.01.D.9826 P a g e...
  • Page 2 COSA Xentaur Corporation reserves the right to revise or to improve the design or specifications of the COSA 9610™ at any time and without notice.

  • Page 3: Table Of Contents

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ Table of Contents 1. INTRODUCTION ............................7 1.1. INTRODUCTION ..........................7 1.1.1. Purpose of the analyzer ......................... 7 1.2. THE COSA 9610™ ANALYZER ......................7 1.2.1. Oven with oxygen sensor ....................... 8 1.2.2.
  • Page 4 2. INSTALLATION ............................24 2.1. GENERAL ..............................24 2.2. STORAGE ..............................24 2.3. PLACEMENT ............................24 2.3.1. General ............................24 2.3.2. COSA 9610™ in general purpose execution ................25 2.4. MECHANICAL CONNECTIONS ......................25 2.4.1. General ............................25 2.4.2. Sample supply ..........................27 2.4.3.
  • Page 5 6. INSTALLATION DRAWING ........................69 7. ORDERING OF SPARE PARTS ........................ 70 7.1 COSA 9610 Standard Temperature Spare Parts List as of 5-2021 ..........70 7.2 COSA 9610 Mid Temperature Spare Parts List as of 5-2021 ............72 8. CERTIFICATION ............................75...

  • Page 6: Introduction

    The continuous COSA 9610™ analyzer determines online the Wobbe-index of a gas. The COSA 9610™ can be used both, as feed forward and feedback analyzer for gases mixing or as a feed forward analyzer for burning control. In order to achieve an optimal performance of the analyzer system it is necessary to read this manual thoroughly before installation and start-up.

  • Page 7: Oven With Oxygen Sensor

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 1.2.1. Oven with oxygen sensor The gas/air mixture is burnt catalytically in an oven, which is kept at 812ºC with a heating spiral. The temperature is maintained with temperature control using a K-type thermocouple.

  • Page 8: Calibration Procedure

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ After the mixing chamber, the mixture flow is divided into an excess flow to vent and a flow to oven. The flow to the burning oven will be approximately 30-50 Nl/hr (500 - 800 Ncc/min).
  • Page 9 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ The analyzer itself controls the timing of the valves switching. When the measured values stay within the specified tolerances, the newly calculated calibration. parameters will be accepted. Otherwise, the analyzer will keep the old value and generates a CAL ERROR on the display and switch the system fault contact and calibration fault contact.

  • Page 10: Extended (Dual) Range Option

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 9. Medium calibration gas is switched off and the high calibration gas is switched on. 10. The analyzer waits for the readings to stabilize up to the “Switch Time”. 11. High calibration gas is switched off and the process gas is switched on.

  • Page 11: Utilities

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ Make Cosa Xentaur Corporation Service Natural gas, fuel-gas, biogas, etc. Wobbe index 0-2730 BTU/scf (0-102 MJ/Nm span 0-1150 BTU/scf (43 MJ/Nm ) (selectable) Ranges CARI 0-20, span 0-10 Accuracy ± 0.4% of measuring value natural gas Repeatability ±0.7 BTU/scf (±0.03 MJ/Nm...

  • Page 12: Connection

    1.6 X-Purge Option 1.6.1. Purpose The COSA 9610™ Calorimeter is protected by a Pepperl & Fuchs X-purge unit. The purge Type X and Ex px purge pressurization system protects general-purpose equipment mounted in a standard enclosure so that it can be located and operated in a hazardous area. The...

  • Page 13: Operation Of X-Purge And Component Kits

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 21. The X-purge operates by controlling and monitoring compressed instrument air through the protected enclosure(s) to remove and prevent the accumulation of flammable gas, vapors, or dust. The X-Purge system features these main parts: •...

  • Page 14: Operation

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 1.6.2.1 Operation The X-Purge consists of the control unit and user interface mounted in a 316L stainless steel Type 4X (IP66) enclosure with the pneumatic solenoid valve mounted on the unit. A proportional valve can be ordered in place of the solenoid valve for continuous control of flow and pressure to the enclosure.

  • Page 15: Pneumatic Manifold With I.s. Solenoid

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ The X-Purge is user programmable for many of the configurable options available. This is done with the intrinsically safe user-interface on the face of the unit, which can also be remote mounted. The user-interface is a 2 x 20 LCD that is programmed through a set of buttons on the menu driven unit.

  • Page 16: Purge Timing

    • 30 SCFM @ 3.4” w.c., (850 l/min @ 86 mm w.c.) The COSA 9610™ uses the first setting of 5 SCFM @ 1.3” w.c. to establish the purge within the enclosures. This volume exchange and purge timing is factory set to 8mins, but can be re-configured to a different value if required by the Area Authority having jurisdiction at the installation site.

  • Page 17: Purging Modes

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ one installation to another. The following parameters must be entered for the dynamic purge time: • Enclosure volume • Number of exchanges The purge time will be based on the measurement of the vent and evaluation of this measurement from the EPCU.

  • Page 18: Outputs

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ The intrinsic safety inputs activate the auxiliary relays, energize the Rapid Exchange valve, de-energize the enclosure contacts, and shut the system down, in addition to many more actions and outputs. 1.6.2.10. Outputs There are (2) normally open dry contacts for the enclosure power that can be energized only after a successful purging and a minimum enclosure pressure is maintained.

  • Page 19: Z-Purge Option

    1.7 Z-Purge Option 1.7.1 Purpose The COSA 9610™ Calorimeter is protected by a Pepperl & Fuchs’ Bebco EPS system type Z rapid exchange purging system, model 1002. It allows the use of general purpose or nonrated non-rated electrical or electronic devices, with exception to devices that produce...

  • Page 20: Operation

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ • Rapid exchange pressure gauge • Venturi orifice • Regulator • EXP pressure loss alarm switch 1.7.2. Operation With the inert gas supply connected, enclosure power deenergized and alarm system energized (if utilized).
  • Page 21 A metallic ball is used in this alarm flowmeter. The PurgemasterTM meter used in The COSA 9610™ Calorimeter is equipped with a min alarm contact. The alarm sensor is suitable for hazardous location because the sensors are intrinsically safe when used with the switching amplifier.

  • Page 22: System Maintenance

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 1.9 System maintenance Maintenance and installation are performed by trained personnel only. Please contact COSA Xentaur for the maintenance schedule. Regular Maintenance Drain the protection system regulator frequently and clean system with nonsolvent cleaning agents only.

  • Page 23: Installation

    Fax: 631-345-5349 We kindly ask you to submit photographs of the damage. If the COSA 9610™ is supplied by the COSA XENTAUR CORPORATION, as part of a complete package and built into a shelter or house, installation may differ from hereunder described.

  • Page 24: Cosa 9610™ In General Purpose Execution

    The COSA 9610™ is supplied on a 304SS freestanding frame. This frame is to be placed on a flat surface (i.e. concrete slab). Two holes in the base of the frame enable the COSA 9610™...
  • Page 25 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ • Use a correct size wrench to lock the body of the fitting and tighten the nut with another correct size wrench for 1- 1/4 turn for 1/4" fittings, 3/4 turn for 1/8"...

  • Page 26: Sample Supply

    2.4.3. Calibration gasses Calibration gas composition is depending on range and process gas. COSA Xentaur can advise suitable compositions. For a single range analyzer, two calibration gasses (low and high value) are recommended.

  • Page 27: Analyzer Electronics (Nec Us Application)

    1/4 turn with a suitable spanner. The supply and drainage tube can now be connected. Because the supply line is under pressure and has been closed off on the COSA 9610™ 28 |...

  • Page 28: Air Orifice Selection

    3.1.2. Air orifice selection Before the COSA 9610™ is set into operation, the range of measurement must be established. The air orifice is selected based on the desired range of measurement. The COSA 9610™ is standard equipped with the following orifices: •...

  • Page 29: Adjusting Booster Relays

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ adjusted based on the application. After this throttle back the output of the analyzer flow to 40 liter/hr (660 CCM or 1.4 CFH) using the needle valve on flow meter tagged "Analyzer flow".

  • Page 30: Start-Up Of The Control Unit

    3.2.2. Programming the measurement parameters Programming the COSA 9610™ is easy with the menu-controlled software. Menu can be navigated using the cursor keys. The key operations are:...

  • Page 31: Main Screen

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ ESC. Then To enter the main menu screen, press screen now presents some functions that can be selected by the cursor keys or by typing the number associated to the menu item. To resume normal operation, press until the main screen to appear.
  • Page 32 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ cal gas 3 Digital output driving high value calibration gas air actuator Extended range execution indicating second range 1 (optional) mixing chamber is selected for dual range option stream 1 (Standard) Indicating process stream 1 selected...
  • Page 33 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 34 | P a g e...
  • Page 34 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 35 | P a g e...

  • Page 35: Programming Menus

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3.3. P ROGRAMMING ENUS The paragraph numbers correspond with the key sequence from the ‘menu tree’. In this way it is easy to see how a specific menu is reached. One exception is the...

  • Page 36: Measurement Menu

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3.3.3. Measurement Menu 37 | P a g e...

  • Page 37: Output Menu

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3.3.4. Output Menu 38 | P a g e...
  • Page 38 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 39 | P a g e...

  • Page 39: Communications Menu

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3.3.5. Communications Menu Submenus 1-3 with default communication settings 40 | P a g e...

  • Page 40: System Menu

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3.3.6. System Menu 41 | P a g e...
  • Page 41 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ Passwords: • USER: 1234 ADMIN: 9999 • Display Menu 42 | P a g e...

  • Page 42: Reset Alarms Menu

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3.3.7. Reset Alarms Menu 3.4. TEMPERATURE CONTROLLED OVEN 3.4.1. Furnace temperature control unit The zirconia cell must operate at a temperature above 600ºC. For optimal performance, a set-point temperature of 812ºC was chosen. The oven that serves as the heating device for the zirconia cell is made of a metal wire-wound heating element.

  • Page 43: Adjustment Procedure Temperature Regulator

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ temperature set-point. The oven needs about half an hour to heat up to 812ºC. Normal on/off-ratio is about 85%. This allows for a stable temperature control and long lifetime of the oven (typically 2 – 8 years).

  • Page 44: Preventive Maintenance

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 4. PREVENTIVE MAINTENANCE 4.1. WEEKLY, MONTHLY, THREE (3) MONTH MAINTENANCE 4.1.1. Filters Inspect three (3) filters, the pressure regulator air filter, gas filter, and coalescing filters, for signs of moisture, water, or liquids. If there is anything that indicate signs of moisture and/or liquids, these filters should be replaced.

  • Page 45: Troubleshooting

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 4.3. T ROUBLESHOOTING Breakdown -> fault report Test Action No air pressure -> flow alarm tube fracture, leak in the system Check for leak Replace tube Measuring pressure behind Open valve for reducing valve...

  • Page 46: Replacement Of Residual Oxygen Sensor And Cell Housing

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 4.4. REPLACEMENT OF RESIDUAL OXYGEN SENSOR AND CELL HOUSING Before going any further make sure that the oven has been disconnected and cooled off so that no physical injury can occur caused by coming into contact with any parts which may still be hot.
  • Page 47 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3. Loosen ½” x ½” x ¼” Reducing Union Tee and remove four (4) #10-32 screws. 4. Slowly remove the oven together with the thermal couple, cell housing, oxygen sensor, and wiring. Lay the oven down on the bottom of the oven compartment.
  • Page 48 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 6. Remove the 1/8” T x 1/8” FNPT elbow fitting and then slide the cell housing out of the oven. Caution O2 sensor and cell housing may be melted together due to the excessive heat inside the oven.
  • Page 49 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 8. Mark the ½” tube at the internal shoulder of ½” x ½” x ¼” Reducing Union Tee. 50 | P a g e...
  • Page 50 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 9. Remove the oven together with the cell housing from the oven compartment back plate. Remove the cell housing out of the oven. Use an appropriate cutting tool to trim off the ½” tube of the cell housing at the mark.
  • Page 51 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 12. Continue to assemble the rest of components in the reverse order. 52 | P a g e...

  • Page 52: Modbus Register List

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 5. MODBUS REGISTER LIST 5.1. COIL REGISTERS 53 | P a g e...

  • Page 53: Discrete Input Registers

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 5.2. DISCRETE INPUT REGISTERS 54 | P a g e...

  • Page 54: Input Registers

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 5.3. INPUT REGISTERS 55 | P a g e...
  • Page 55 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 5.4. H OLDING EGISTERS 56 | P a g e...
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  • Page 67: Variable List

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 5.4. VARIABLE LIST 68 | P a g e...

  • Page 68: Installation Drawing

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 6. INSTALLATION DRAWING 69 | P a g e...

  • Page 69: Ordering Of Spare Parts

    Please call and reference the below part number for current spare parts pricing. Immediate pricing is available to all confirmed customers. 7.1 COSA 9610 Standard Temperature Spare Parts List as of 5-2021 SAMPLE CONDITIONING SYSTEM – General Spares 3-5 Year CAL.98.M.0010...
  • Page 70 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3-5 Year CAL.98.M.0009 Tee filter 1 Year CAL.98.M.0025 Filter Element for Tee Filter 1 Year XD0.98.M.5023 Coalescing Filters 10/Pack SPECIFIC GRAVITY CELL Low Temp Density Cell Assembly 5+ Year CAL.S4.M.10003 c/w Density Cell Converter Board GAS &...

  • Page 71: Cosa 9610 Mid Temperature Spare Parts List As Of 5-2021

    Pump Overhaul Kit – TFE FLOW ALARM OPTION 5 Year ESS.98.M.0666 Flow Alarm Option 7.2 COSA 9610 Mid Temperature Spare Parts List as of 5-2021 SAMPLE CONDITIONING SYSTEM – General Spares 3-5 Year CAL.98.M.0010 Air Filter Regulator/ Air Regulator 1 Year CAL.98.M.0241...
  • Page 72 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3 Year CAL.98.M.0055 Pressure Gauge, 0-60PSIG, mid-temp 5 Year CAL.98.M.0237 Manifold Block 3-Module 3-5 Year CAL.98.M.0315 Flow Indicator 10-1000 CCM 3-5 Year CAL.98.M.0316 Flow Indicator 1-30LPM SS Valve 3-5 Year CAL.98.M.0008 Flame Arrestor for SCS 5 Year CAL.98.M.0117...
  • Page 73 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 3-5 Year CAL.98.M.9765 Cell Housing with screens ½” vent tube Cell Housing with screens 1/4” vent tube – 3-5 Year CAL.98.M.0030 9600 only 5 Year CAL.18.E.0003 Inner cell connector cable 5 Year CAL.18.E.0004...

  • Page 74: Certification

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 8. CERTIFICATION 1. ATEX CERTIFICATE 2. US/CANADIAN CERTIFICATE 3. IECEx This product has been examined against the following standards 1. ATEX: EN 60079-0:2009 EN 60079-2:2007 EN 60079-11:2007 EN 60529 (+A1):2000 2. US/CANADA:...
  • Page 75 INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™ 76 | P a g e...

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