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New Cosmos Electric PS-8 Series Instruction Manual For Installation

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PS-8 Series Gas Detector
for use in semiconductor manufacturing plant
Instruction Manual for Installation
Keep this manual for easy reference.
Read and understand this manual carefully before using this product correctly.
This manual describes the standard model. If your unit has end-user-specific options, this manual will be
superseded by your delivery specifications.
Instruction Manual No.
GAE-178-00
December 2024

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Summary of Contents for New Cosmos Electric PS-8 Series

  • Page 1 PS-8 Series Gas Detector for use in semiconductor manufacturing plant Instruction Manual for Installation Keep this manual for easy reference. Read and understand this manual carefully before using this product correctly. This manual describes the standard model. If your unit has end-user-specific options, this manual will be superseded by your delivery specifications.

  • Page 2: Related Manuals

    The following documents have been prepared to guide your installation and use of this product. PS-8 Series Instruction Manual for Installation (this document), No. GAE-178 This document is intended for your supervisors and service personnel who are concerned with the installation of this product.

  • Page 3: Introduction

    Introduction Thank you for purchasing the New Cosmos PS-8 series extractive type gas detector (“product” or “unit” hereafter). Prior to use, please read this manual as well as the related manuals and follow the instructions provided for correct use of the product.
  • Page 4 Danger, Warning and Caution, depending on the severity and magnitude of the risks. Carefully read the contents related to the precautions before operation and maintenance work. This manual uses Danger, Warning, Caution and Notice symbols to draw attention to procedures, materials, methods, and processes that require particular attention.

  • Page 5: Model Variations

    Model Variations This product is divided into the following models according to the sensor unit and functions that meet the customer's specifications. Main Unit Collective Power Supply Output Signal Model Contact Output 24 VDC Ethernet Analog Signal (AL1, AL2 and Fault) PS-8M ✔...

  • Page 6: Quick Index

    Quick Index This page lists parts that may be often referenced. Prior to use, please read the precautions in 1 "General Precautions". Unit Dimensions and Components Pages 7 to 16 Installation Pages 20 to 34 Wiring Connection Pages 35 to 42 Master device...

  • Page 7: Table Of Contents

    1 General Precautions Table of Contents Related Manuals ............................i Introduction ............................... ii Notation Rules for Registered Trademarks ..................ii Precautions ............................ii Symbols Used in this Instruction Manual ..................ii Model Variations ..........................iv Quick Index ............................... v General Precautions ......................... 1 1.1 Before Work ..........................
  • Page 8 1 General Precautions 7.4.1 Cable Work ........................35 7.4.2 Connecting Power and Signal Lines ................37 7.4.3 Ground Connection ....................... 40 7.4.4 Connection to External Devices ................... 41 7.4.5 Front Module Installation ....................41 7.5 Tubing Connection ........................43 7.5.1 Tubing Work ........................43 7.6 Sensor Unit Installation ......................

  • Page 10: General Precautions

    1 General Precautions General Precautions 1.1 Before Work In order to ensure safe use, please carefully read the precautions in this manual before turning on the product to prevent unexpected accidents. New Cosmos is not liable for any cost incurred or any damage resulting from any usage other than that outlined in this document.

  • Page 11: Labels Affixed To Product

    1 General Precautions • Do not use radio wave-emitting devices (e.g., walkie-talkies, cell phones, wireless devices) in the vicinity of the product. • Do not disassemble, modify, or alter the structure of the product or its electrical circuits. Doing so may compromise product performance. •...
  • Page 12 1 General Precautions Labels for Main Unit and Subunit Item Description Serial number label ① Indicates the serial number of the product. Power rating label ② Indicates the model and the power supply specifications. Environmental label ③ Indicates the applicable certification markings. Pump serial number label ④...

  • Page 13: Disposal

    The service life of this product is 10 years. The unit can operate for up to 10 years with standard installation and operation in accordance with the PS-8 series instruction manuals for installation and operation. When the service life has expired, replacement is essential for continued reliable performance and other purposes.

  • Page 14: System Configuration

    2 System Configuration System Configuration This section explains the PS-8 system configuration. Up to three subunits and up to four expansion units (up to eight modules, two modules per expansion unit) can be connected to a single main unit to form a gas detection system (a maximum of 4 channels or 4 gases).

  • Page 15: Package Contents

    － Flat-bladed screwdriver Use to open/close the terminal block’s slots Instruction Manuals for Installation, Operation, PS-8 series instruction manual set and Communication *Sensor unit is not included and sold separately. It will be separately delivered when ordered. Subunit and Accessories Item Qty.

  • Page 16: Unit Dimensions And Components

    4 Unit Dimensions and Components Unit Dimensions and Components 4.1 Main Unit (M) 4.1.1 Exterior Appearance (Dimension unit : mm) Item Component Description ① Front case A combination of a front case and a front cover is called “front ② Rear case module”.

  • Page 17: Led And Keys

    Blinking rapidly: when the unit is in maintenance mode 2. Lit: when the unit is in aging mode. Displays gas concentration values, alarm statuses, etc. Refer to 4.1.4 “LCD” of the PS-8 Series Instruction Manual for ⑥ Operation for details. Left key Used to select an item or cancel the current operation.

  • Page 18: External Wiring Terminals

    4 Unit Dimensions and Components 4.1.3 External Wiring Terminals Do not touch the jumper pins inside. They are for device setting. Jumper Pin (2 places) Identifier Terminal Description 24 VDC (+) INPUT Power input 24 VDC ( − ) − 24VDC Earth 1st stage gas alarm contact output that is...

  • Page 19: Subunit (S1/S2/S3)

    4 Unit Dimensions and Components 4.2 Subunit (S1/S2/S3) 4.2.1 Exterior Appearance (Dimension unit : mm) Item Component Description ① Front case A combination of a front case and a front cover is called ② Rear case “front module”. ③ Front cover ④...

  • Page 20: Leds

    4 Unit Dimensions and Components 4.2.2 LEDs Item Component Description Indicates the operational status. The LED status will take precedence in Blinking rapidly > Blinking > Lit. Power LED Not lit: when the unit is off. ① (Green) Blinking: when the warm-up is in progress. Blinking rapidly: when the sensor is off.

  • Page 21: Address Switches On Rear Case

    4 Unit Dimensions and Components 4.2.3 Address Switches on Rear Case Item Component Description Adress switches DIP switches for setting the address of the subunit. ① Ref. Refer to 7.3.1 “Subunit Address Setting” for how to set the address.

  • Page 22: Expansion Unit (Eu)

    4 Unit Dimensions and Components 4.3 Expansion Unit (EU) 4.3.1 Exterior Appearance (Dimension unit : mm) Item Component Description Front case ① － Rear case ② － Case fixing latch Secures the rear case to the front case. ③ Case release lever Releases the front case from the rear case.

  • Page 23: External Wiring Terminals

    4 Unit Dimensions and Components 4.3.2 External Wiring Terminals AO Module (Analog Output) (AO1 − AO4) Item Component Description DIP switches for setting Address the address of AO ① switches module *Used when adding an AO module. Terminal Identifier Terminal Name Description Earth Earth...
  • Page 24 4 Unit Dimensions and Components DO Module (Contact Output) (DO1 − DO8) Item Component Description DIP switches for Address setting the address of ① switches DO module *Used when adding a DO module. *Do not touch the jumper pins inside. They are for device setting.
  • Page 25 4 Unit Dimensions and Components AI Module (Analog Input) (AI1 − AI4) Item Component Description DIP switches for setting the Address switch ① address of AI module *Used when adding an AI module. Terminal Identifier Terminal name Description Analog input + (4-20 mA) 1S −...

  • Page 26: External Outputs

    5 External Outputs External Outputs When shipped, the relay contacts (gas and fault alarm contacts) have been set as per the delivery specifications specified at the time of ordering. A. When the relay contacts are set to the “normally de-energized” option The relay contacts are not energized during normal operation, and they are energized when an alarm is activated.
  • Page 27 5 External Outputs Analog Output Allocation (Allocating the AO module’s output or the main unit’s output to the channel) • f an AO module, not the main unit, is allocated to the channel, the analog output from the main unit will be fixed at 0.5 mA. If the analog output allocation target is switched from the main unit to the AO •...

  • Page 28: Preparation

    6 Preparation Preparation 6.1 Tools Required The below tools required for installation are not included, and should be prepared by the user:  Phillips screwdriver (#2) for M4 screw  Spanner or monkey wrench  Flat-bladed screwdriver (blade width: 3.0 mm) 6.2 Disposal of Packing Materials The packing materials (e.g., corrugated cardboard, plastic bags) used to enclose the product and optional items should be disposed of in accordance with the applicable local laws and regulations.

  • Page 29: Installation

    7 Installation Installation This chapter describes the installation flow and procedures. Ensure proper installation in accordance with the given specifications. Perform installation in the following order. When using a main unit as a stand-alone detector, device settings (refer to 7.3 “Device Settings”) are not necessary.
  • Page 30 7 Installation • This product is not explosion-proof and must not be installed in a hazardous area. • Do not use organic solvents for cleaning the product. Organic solvents may negatively affect the product’s exterior as well as internal components. •...

  • Page 31: Installation Location

    7 Installation 7.1 Installation Location 7.1.1 Installation Conditions Install the product in a highly visible and easily accessible position, so that the situation can be easily recognized and addressed in the event of an emergency. The required space for installation is explained below.

  • Page 32: Installation Procedure

    7 Installation Installation at Raised Position The installation of the product in a high place is not recommended; however, if you need to install it in a high place, ensure that enough space is left below the product to allow for inspection or maintenance which may require a stepladder, among others.
  • Page 33 7 Installation Pull the front module forward to separate it from the rear case. Rear Case Expansion Unit Pull the latch open. Latch Front Module Pull the front module forward while pulling the case release lever. The front module will separate from the rear case.

  • Page 34: Wall-Mounting

    7 Installation 7.2.2 Wall-Mounting Mounting a Single Unit of main unit Cut two mounting holes in the wall as shown below. Install a wall anchor or plug into each of the mounting holes. Main Unit M4 mounting hole (2 places) Install the two provided screws (M4x12) into the mounting holes in the wall through the holes on the rear case.
  • Page 35 7 Installation Mounting Multiple Units Connect subunits to the right of the main unit and the expansion units to the left of the main unit. If incorrectly connected, malfunction may occur. Expansion Unit Expansion Unit Main Unit Subunit Subunit Subunit Cut mounting holes in the wall as shown below.
  • Page 36 7 Installation Install the provided screws (M4×12) into the mounting holes in the wall through the holes on the rear cases (two holes per unit). Screws (2 places) Connect each pair of the adjacent units with a joint. Ensure that the ribbed side of each joint is facing the wall.

  • Page 37: Joint Removal

    7 Installation 7.2.3 Joint Removal Tools Required  Flat-bladed screwdriver (blade width: 3.0 − 5.0 mm) Removal Procedure Insert the flat-bladed screwdriver into the joint (circled area). Joint Tilt the flat-bladed screwdriver in the direction of the arrow to disconnect the connector on one side.

  • Page 38: Din Rail-Mounting

    7 Installation 7.2.4 DIN Rail-Mounting Install the product in an environment free from shock and vibration. Secure both ends of the DIN rail with mounting brackets if necessary. Do not install the product in a place prone to shock and vibration. Failure to do so may damage the product.
  • Page 39 7 Installation Mounting Multiple Units Connect the subunits to the right of the main unit and the expansion units to the left of the main unit. If incorrectly connected, malfunction may occur. Remove the connector cover between each pair of adjacent units. Connector covers Hook the tabs (2 places per unit) on the rear case onto the upper edge of the DIN rail.
  • Page 40 7 Installation Connect each pair of the adjacent units with a joint. Ensure that the ribbed side of each joint is facing the wall. Attach the connector cover to the unit at each end. Connector cover Joints Wall Ribs Joint Connector cover Ensure that the joints are correctly aligned before insertion, as forcing them in may cause damage.

  • Page 41: Device Settings

    7 Installation 7.3 Device Settings When connecting a subunit or when adding a module of the same type, device settings are required. When using the main unit as a stand-alone detector, no device settings are required. 7.3.1 Subunit Address Setting Set the address for each subunit using the address switches (DIP switches) according to the table below.

  • Page 42: Expansion Module Removal

    7 Installation 7.3.3 Expansion Module Removal *Expansion module: AO module, DO module, or AI module When removing the expansion module, follow the steps given below. While pressing the module release levers (2 places), pull down to open the bottom. Expansion Unit Module Release Lever (2 places) Pull the module downward.

  • Page 43: Expansion Module Installation

    7 Installation 7.3.4 Expansion Module Installation When installing the expansion module, follow the steps given below. Place the module in the slit on the bottom. Slit Lift the bottom close to secure the module to the case.

  • Page 44: Wiring Connection

    7 Installation 7.4 Wiring Connection 7.4.1 Cable Work Take care to avoid damaging the cables during installation and wiring. While performing wiring for the maintenance or addition in some connected units (not all), remove the front modules of the adjacent units. •...
  • Page 45 7 Installation PS-8EU AO Module (Analog Output) Terminal Identifier Description Earth 1.25 mm single-wire cable (Green) 1G + Analog output ① 1H − CVVS (1.25 mm ) 2-wire cable 2G + Analog output ② 2H − CVVS (1.25 mm ) 2-wire cable 3G + Analog output ③...

  • Page 46: Connecting Power And Signal Lines

     Ensure that the Ethernet cable length to the hub is 100 m or less.  Please refer to the PS-8 Series Instruction Manual for Operation as well. Terminal Block Specifications • Solid and stranded wires can be connected to the terminal blocks without wire ferrules nor soldering, but it is recommended to use wire ferrules to prevent unraveled or stray wires.
  • Page 47 7 Installation Installing Wire into Terminal After connecting the wires to the terminals, ensure that they are securely in place. Check for any loose strands or exposed bare wires outside the terminals, as failure to do so may result in electric shock or damage to the product. Fully insert the flat-bladed screwdriver into the square slot on the terminal block to open the corresponding round slot.
  • Page 48 7 Installation Connecting to Modbus TCP (Ethernet) for PS-8M Connect the Ethernet cable to the main unit. If the switching hub is not PoE-compliant, provide 24 VDC to the main unit. Switching Hub Switching Hub Master Device Typical Modbus TCP (Ethernet) Configuration...

  • Page 49: Ground Connection

    7 Installation 7.4.3 Ground Connection Wiring and installation must be only performed by a qualified electrician with sufficient knowledge of wiring/installation procedures in accordance with the applicable technical standards. (1) Typical wiring when 24 VDC is provided External Controller Shielded Cable Shielded Cable Shield Shield...

  • Page 50: Connection To External Devices

    7 Installation 7.4.4 Connection to External Devices Connecting to an external controller or annunciator Normally open or closed dry contacts are turned on/off for activating/deactivating a 1st stage gas alarm, 2nd stage gas alarm, and fault alarm. • New Cosmos is not liable for any cost incurred or any damage resulting from controlling external equipment (e.g., interlock) by using the product’s outputs (e.g., analog output, alarm contact output).
  • Page 51 7 Installation While pushing the front case, close the latch on the top of the rear case. Close the latch Push the front case Ensure that the lever is in the lock position after closing the latch. If the latch and lever are not in the lock position, the case will loosen or open, which may cause injury or product damage such as a broken LCD.

  • Page 52: Tubing Connection

    ), remove the filter element (FE- 1) from the filter unit (MF-50). Correct detection is not possible if the filter element is present. Refer to 12.3.1 “Filter Element Replacement” of the PS-8 Series Instruction Manual for Operation for the removal procedure.
  • Page 53 7 Installation • Do not use a gas collector in a confined space (e.g., inside a duct). • The pressure differential between the gas inlet/outlet and the outside air pressure (atmospheric pressure) should be within ± 1kPa. In addition, the pressure differential between the gas inlet and the gas outlet should be within 1kPa, with negative pressure applied to the gas inlet.
  • Page 54 7 Installation Install the PP half union (provided) into the gas inlet. When connecting the PP half union (provided) to the gas inlet, secure the filter unit with one adjustable wrench or spanner, etc. to prevent the filter unit from rotating and another to install to the PP half union.

  • Page 55: Sensor Unit Installation

    7 Installation 7.6 Sensor Unit Installation • Check that the target gas and full scale value are correct before using a sensor unit. Also, check that the sensor expiration year/month has not been reached. Note: The target gas name, full scale value and expiration year/month are indicated on the sensor unit.

  • Page 56: Power-On Check

    7 Installation 7.7 Power-on Check After the installation, turn the product on and check that it starts up normally. Take the following steps to turn on the product. • The load current and voltage should not exceed the product’s relay contacts’ rating. Turn on the product while no gas is present around the gas sampling inlet.
  • Page 57 7 Installation If this is the initial power-up, the Fault LED will start blinking and【 】will appear on the screen. Press and hold [ ] until the lock icon disappears to deactivate the safety lock. Lock Icon Press and hold [ ] and [ ] simultaneously while on the gas concentration screen to set all the channels to maintenance mode 2 at the same time.
  • Page 58 7 Installation 11. Press and hold [ ] and [ ] simultaneously while on the gas concentration screen to perform the auto channel allocation. Channel numbers for the connected sensor units Pressing and holding [ ] and [ ] simultaneously while on the gas concentration screen will automatically allocate all the connected units and modules (from the main unit, the subunits, to the AI modules) to the channels (from the youngest number to the oldest).
  • Page 59 7 Installation 12. Check the auto channel allocation result. (1) Press and hold [ ] to go to Menu. (2) Select “Individual CH Info.” to go to the Individual CH Info screen. To return to Menu, press and hold [ Channel Number Check the items “Analog output allocation”...
  • Page 60 2 at the same time. Check that the Manit LED blinks and “MAINTE2” appears on the screen. 14. Perform an initial checkup. For the check procedure, refer to 12.2 “Check/Inspection Procedure” in the PS-8 Series Instruction Manual for Operation.

  • Page 61: Specifications

    8 Specifications Specifications 8.1 Main Unit Model PS-8M, PS-8N Detection Principle Electrochemical, Hotwire semiconductor, Galvanic cell Gas Sampling Method Extractive type (0.5L/min) Flow rate automatically controlled PTFE with OD 6mm ID 4mm or OD 1/4 inch ID 11/64 inch Sampling Tubing Tube length to be at least 1 m but not more than 20 m Target Gas (As per the delivery specifications)
  • Page 62 8 Specifications Model PS-8N PS-8M Terminal: Terminal blocks (3-pin x 1 and 6-pin x 1) Applicable cable: CVV 1.25mm² Target signal: Power, gas alarm contact (1st and 2nd stages), and fault alarm contact signals Terminal: RJ-45 jack 8P8C None Applicable cable: STP Ethernet cable, Category 5e Applicable Cable for or higher External Terminals...

  • Page 63: Subunit

    8 Specifications 8.2 Subunit Model PS-8S Detection Principle Electrochemical, Hotwire semiconductor, Galvanic cell Gas Sampling Extractive type (0.5L/min) *Flow rate automatically controlled Method PTFE with OD 6mm ID 4mm or OD 1/4 inch ID 11/64 inch Sampling Tubing Tube length to be at least 1 m but not more than 20 m Target Gas (As per the delivery specifications) Detection Range...

  • Page 64: Expansion Unit

    8 Specifications 8.3 Expansion Unit Model PS-8EU AO Module DO Module AI Module Module Type (Analog output) (Contact output) (Analog input) Gas alarm contacts (1st and 2nd Signal Gas concentration analog signal stages) and Fault alarm contact Number of Outputs 4-20 mADC (common negative External with power supply)

  • Page 65: Glossary

    9 Glossary Glossary Term Definition Gas detector Device used to detect the presence of a target gas and to give its (or gas detector head) concentration in the form of an electrical signal. Specific gas to be detected, concentration displayed, and used to Target gas trigger alarms.
  • Page 66 Revision GAE-178-00 December 2024 00 (Initial issue) Additional copies of this instruction manual may be purchased. Contact New Cosmos or its authorized representative for ordering. Authorized representative: Manufacturer: NEW COSMOS ELECTRIC CO., LTD. 2-5-4 Mitsuya-naka, Yodogawa-ku, Osaka 532-0036, Japan www.newcosmos-global.com...

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