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Compur Monitors Statox 560 Operator's Manual

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Operators Manual
Statox 560

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Summary of Contents for Compur Monitors Statox 560

  • Page 1 Operators Manual Statox 560...

  • Page 2: Table Of Contents

    3.3 Statox 560 Cable Tail Version Connection .................... 9 3.4 Statox 560 connecting the eXLink-Plug ....................10 3.5 Connecting Statox 560 to a Statox 502 Control Module ..............12 3.6 Connecting the Remote Self-test ......................13 3.7 Connection to the Open-Drain switching outputs ................14 3.8 Stand-alone operation ........................
  • Page 3 1 ppm 562922 ................57 11.3 Statox 560 Sensor Module COCl 50 ppm 562924 ................58 11.4 Statox 560 Sensor Module HCN 20 ppm 562930 ................59 11.5 Statox 560 Sensor Module HCN 100 ppm 562934 ................60 11.6 Statox 560 Sensor Module Cl 5 ppm 562910 ...................

  • Page 4: Safety Advice

     Read and observe this manual carefully. Store it in safe place.  The Statox 560 is only allowed to operate under the given ambient conditions (see Technical Data, chapter 10).  In particular the regulations with regards to the protection regulations for instance DIN EN 60079- 14 must be observed.

  • Page 5: Product Description

    The Statox 560 sensor head is explosion proof group II category 2. It is designed to comply with the requirements for installation in zone 1 and zone 2. The Statox 560 sensor head can be operated as a stand - alone unit, or as a 4-20 mA transmitter.

  • Page 6: Installation And Connection

    Statox 560 3 Installation and Connection Compur Monitors recommends to use fine mashed cable  0.75 mm² for instance type Oelflex 415 CP. 3.1 Maximum distance to the power supply The maximum cable length depends on the gas to be measured (different power requirements of the different gas generators) and the cable lead diameter.

  • Page 7: Mounting

    Leaving the stainless steel protective cylinder and the protective cap on the instrument protects it from pollution. Install the Statox 560 sensor head in upright position to the wall. Use two M8 screws and suitable washers. Maximum 15 ° deviation from the upright position is acceptable. See below the dimensions inclusive the space needed for easy access in brackets.
  • Page 8 Statox 560 Ø 8,3 Picture 2: Statox 560 dimensions in mm and the space needed for safe and easy operation. Outer dimensions and drill plan of the junction box, article number 562988. Do not open the blue flame - proof housing!

  • Page 9: Statox 560 Cable Tail Version Connection

    The cable tail must be connected to a suitable EMC junction box made of metal. When installed in a hazardous area this must be certified Ex e and have 10 terminals and EMC resistant cable glands. Statox 560 must be operated with 24 (16-30) VDC. Connecting it to higher voltages or short circuiting the outputs may destroy it.

  • Page 10: Statox 560 Connecting The Exlink-Plug

    3.4 Statox 560 connecting the eXLink-Plug The Statox 560 eXLink-Version (7 pole) has a plug installed in the housing. The counterpart must be installed by the user and can be connected to a junction box if necessary. The eXLink can be connected and disconnected in hazardous areas without hot work permit.
  • Page 11 Use only coupling Compur # 805594. Observe its installation instructions.  Take care for correct wiring! Wrong pin assignment may damage the Statox 560!  Do not try to dismount the eXLink from the sensor head. This is a potted joint.

  • Page 12: Connecting Statox 560 To A Statox 502 Control Module

    Picture 5: Pin assignment Statox 560 eXLink-plug 3.5 Connecting Statox 560 to a Statox 502 Control Module Here is the procedure how to connect a Statox 560 sensor head to a Statox 502 Control Module (Article number 557000):  First select the appropriate program of the Statox 502 Control Module. Observe the installation instructions and the program listing of the 502 Control Module! ...

  • Page 13: Connecting The Remote Self-Test

    Power 0V Read and observe point A to E in chapter 3.3! Picture 6: Connect the Statox 560 to a Statox 502 Control Module Wrong pin assignment may destroy the Statox 560 or the Statox 502! 3.6 Connecting the Remote Self-test Pin No.

  • Page 14: Connection To The Open-Drain Switching Outputs

    3.8 Stand-alone operation If you want to run the Statox 560 in stand-alone mode (only switching outputs are connected) you have to short pin number 3 and 4 (see Picture 6) directly in the junction box. This way an ammeter is simulated and an error code 2 massage is avoided.

  • Page 15: Product Characteristics

    4 Product characteristics 4.1 Housing The upper part of Statox 560 is an Ex d certified housing with window. This part is sealed and may not be opened by the user. A repair is only possible at Compur Monitors. The Ex d housing must not be opened by other than Compur Monitors personnel or trained...

  • Page 16: Leds

    Statox 560 4.3 LEDs 4 LEDs signalize the actual system status of Statox 560: Name Color Function Power supply: Green „ON“ : Power is on. „Off“:Power is too low or off. Yellow Alarm relay A1 is activated, alarm threshold A1 has been exceeded.

  • Page 17: Sensor Module

    5 Getting started and menu navigation Before you connect the Statox 560 to power, check for correct wiring to avoid any damage of the system! After connecting to power, the current firmware number, date and time will be displayed for min. 5 sec each.

  • Page 18: Start - Up, Connecting The Sensor Module

    – and calibration parameters are loaded. In case these cannot be read, see chapter 6.2. 6. The Statox 560 will give you the warning „Change of sensor type!“, in case it has been operated with a different sensor module before. If you really want to change the gas or range, confirm with .
  • Page 19 Statox 560 8. After the warm-up, the Statox 560 goes into the measuring mode. Allow 60 minutes for stabilization and acclimatization, then proceed a zero adjustment (see chapter 5.3.3) to improve the accuracy. The following settings must be done after the start-up: ...
  • Page 20 Statox 560 Power On Firmware 01.02 2016-06-16 10:33 Sensor detected? SENSOR Loading Parameter Change of sensor type! → OK remove sensor module COCL2 50,0 ppm Version 02.3.01 Change Sensor Replace (flashing) Sensor No. 19718 b. b.: w 3/2016 connect sensor...

  • Page 21: Menus

    5.2 Menus 5.2.1 General The Statox 560 is operated via 4 buttons at the sight glass. These are activated by a magnetic pin, by holding it shortly onto the glass over the relevant button. The Statox 560 menu hast two levels: ...

  • Page 22: Accessing The Service Menu

    During the service menu no measured values are transmitted, no alarms are generated, existing alarms are inhibited. 5.3 Menu overview These schematics give an overview of the main menu of the Statox 560 and a short description. Details of the sub – menus start from chapter 5.3.1. Page 22 of 66...
  • Page 23 Statox 560 Measuring mode Service Code = 1994 Short description: Prooftest Prooftest start Self - test start, set self - test schedule Selftest Calibration Sensor calibration Change Sensor Sensor module replacement Errors Info Error Code info 6 - 16 Alarm history...

  • Page 24: Prooftest

    Statox 560 5.3.1 Prooftest A prooftest checks the sensor head response to gas without triggering an alarm. It can be activated without entering the password - protected service menu. During the prooftest the sensor head is in the service mode, i. e. the output signal is on the preset value and the alarms are inhibited.

  • Page 25: Self-Test

    Statox 560 5.3.2 Self-test The Statox 560 performs an automatic self – test with gas every 24 h. The sensor module includes a gas generator cell, generating a small concentration of the gas to be measured. This give you a reliable information, if the sensor head is working properly.

  • Page 26: Submneu Self-Test - Info

    Statox 560 The Self – Test Menu: The self – test menu includes 4 sub menus. Measuring mode Selftest Selftest Selftest Selftest Selftest Monitoring OFF Start time 08:00 Manual Start Info Picture 14: Submenu of the self-test menu 5.3.2.1 Submneu Self-Test - Info In this menu you can read the time and result of the most recent 5 tests.

  • Page 27: Submenu Self-Test - Manual Start

    Statox 560 5.3.2.2 Submenu Self-test - Manual Start In this menu you can manually trigger a self –test. Just confirm with to start. Temperature and sensor signal will be checked.  If temperature is out of specifications, the test will not start. The display shows „Temp. out of selftest range“...

  • Page 28: Submenu Self-Test - Start Time

    Statox 560 5.3.2.3 Submenu Self-test – Start time Here is how to schedule the self-test. Access only in the service menu. Once entering this menu, you must finish it completely. The factory setting for the self-test start time is 8:00 a.m.

  • Page 29: Submenu Self-Test - Monitoring

    Statox 560 5.3.2.4 Submenu Self-test - Monitoring The menu „Selftest - Monitoring“ activates the output signal during the self-test. This allows to record the test process and response curve. The ex – works setting is OFF. This can only be changed in the service menu! When „Monitoring ON“...

  • Page 30: Calibration

    You need a Statox 560 calibration adapter art.# 562984, an inert gas tube (i.e. art. # 556710) and span gas within the specified concentration range (see Chapter 11). If you are not sure, if you are working in clean atmosphere, use synthetic air for zeroing.
  • Page 31 Statox 560 8. When the sensor head has found a plateau, the sensor head requires to enter the span gas concentration in ppm. The display shows the last used concentration, change with the arrow buttons and confirm with 9. After saving the concentration the display shows „Calibration done“ and the actual concentration in the gas adapter.
  • Page 32 Statox 560 Measuring mode Calibration Calibration Info Calibration 2016-04-30 18:15 Start Displays the last valid calibration. Zeroing Please wait Zeroing Zero Error 5 (6) found? Please wait Zero found Apply span gas No gas detected Apply span gas Gas is on...

  • Page 33: Change Sensor - Sensor Module / Sensor / Generator Cell Replacement

    Statox 560 5.3.4 Change Sensor – Sensor Module / Sensor / Generator Cell Replacement 5.3.4.1 Sensor module replacement In menu „Change Sensor“ you can replace the sensor module. In this menu the sensor head is in the service mode, the timeout deactivated. Thus you will not create an alarm when removing the sensor module.

  • Page 34: Sensor And Generator Cell Replacement

    Statox 560 8. If the measuring head has operated with a different sensor type, you get the message „Change of sensor type!“. If you really want to change, confirm with . This is intended to prevent the user from connecting a wrong sensor module. If you don’t want to work with the plugged module you can easily remove the module by pulling it down.
  • Page 35 Statox 560 Sensor replacement: Unplug the old sensor. Extract and remove the short circuit bridge of the new sensor if there is any. Plug the new sensor, the position of the sensor plug is remote to the module PCB (connect the red wire of the flat ribbon cable to pin 1).
  • Page 36 Statox 560 Measuring mode Change Sensor Change Sensor Unscrew the protection cylinder, Replace unplug the sensor module Change Sensor Plug the sensor module Replace (flashing) Loading Parameter Change of sensor type! →OK Unplug the sensor module COCL2 50,0 ppm Version 02.3.01...

  • Page 37: Errors Info

    Statox 560 5.3.5 Errors Info In menu „ERRORS INFO“ you can check for recently occurred errors. It has no sub – menus. A listing of potential error codes you will find in chapter 6.2. 5.3.6 Alarm History In menu „ALARM HISTORY“ you can check the recent 3 concentration alarms A1 and A2. You can read in each case the alarm start time, concentration maximum and the alarm end time.

  • Page 38: Sensor Info

    Statox 560 5.3.7 Sensor Info The menu „SENSOR INFO“ gives you information about the following parameters:  Gas, measuring range and parameter set of the sensor  Serial number and best before date of the sensor (best before format calendar week / year) ...

  • Page 39: Temperature

    Statox 560 5.3.8 Temperature In this menu you can read the measuring head temperature in °C. There are no further functions. 5.3.9 Firmware This menu provides information of the measuring head firmware version. There are no further functions. 5.3.10 Alarm Relays In this menu you can program the alarm relays for A1, A2 and MR.
  • Page 40 Statox 560 Measuring mode Alarm Relays Alarm1: 10.0 ppm Alarm Relay MR Alarm2: 20.0 pm reset / active Alarm = active reset / active Alarm Relay SR Alarm1: 10.0 Alarm2: 20.0 Alarm = active reset active reset active Picture 27: Schematics alarm relays Procedure: 1.

  • Page 41: Real Time Clock

    Statox 560 5.3.11 Real Time Clock The clock is ex-works set to central European time CET. If necessary set to local time. The clock is battery buffered. Settings must be done in the service menu. Only a correct setting of the local time makes sure you get a correct alarm history.

  • Page 42: Service Output

    Statox 560 5.3.12 Service Output In menu „Service Output“ you can set the analog output to 2 or 4 mA during service. Ex – works setting is 2 mA. The setting must be done in the service menu. Procedure: ...

  • Page 43: Function Test

    Statox 560 5.3.13 Function Test In Menu „Function Test“ you can test the function of the display, the analog output and the alarm outputs. Access only in the service mode. In this menu a timeout of 30 minutes is valid.
  • Page 44 Statox 560 Measuring mode Function Test Function Test Function Test Function Test Alarms mA Output Display Function Test Function Test mmmmmmmmmmmmmmmm Output = 0 mA mmmmmmmmmmmmmmmm Alarm 1 Function Test mmmmmmmmmmmmmmmm Function Test mmmmmmmmmmmmmmmm Output = 2 mA Alarm 2...

  • Page 45: Maintenance Request

    Statox 560 5.3.14 Maintenance Request In menu „Maintenance Request“ you can program whether maintenance request shall be signalized on the analog output. Ex – works setting is „NO“. Access the service menu to change settings! Possible alternative settings:  Maintenance request = system failure = permanent 0 mA.

  • Page 46: System Status And Error Messages

    If the display is dark and green LED off, the power supply voltage is off, too low or its polarity is wrong. If none of this is the case, it could be a broken fuse. Replacement of the fuse must be done by Compur Monitors! 6.1 System Status...

  • Page 47: Error Messages

    Statox 560 6.2 Error messages The Statox 560 internal diagnosis differentiates between “System failure” (SF) and “Maintenance Request” (MR). A system failure is a fatal dysfunction. The system is unable to operate. Except power outage these errors are shown on the display.
  • Page 48 Statox 560 Error Meaning / Reason Rating Correction Delete with RESET, if the problem persists call your Pump failure during measuring mode. Compur representative. Delete with RESET, if the problem persists call your Hardware problem Compur representative. Check for plausibility, eventually expose sensor to synthetic air.

  • Page 49: Maintenance And Cleaning

    Check regularly for pollution, especially the area of the gas entry.  Clean the Statox 560 with a humid cloth. Do not use any detergent, solvent, or water jet.  If the Statox 560 is operated as a SIS requiring functional safety, a regular prooftest is mandatory.

  • Page 50: Accessories And Spare Parts

    Ex e junction Box (10 conductors) 562988 eXLink coupling 6+1 wire 805594 Statox 502 Control Module 557000 Statox 560 calibration adapter 562984 1 meter gas hose 4 x 1 556710 Statox 560 pump 562982 Statox 560 magnetic pen...

  • Page 51: Functional Safety

    9.1 Safety Functions Safety Function 1 (SF1) The Statox 560 including gas sensor detects a toxic gas. The concentration is monitored at the analog output as current in the range 0 - 22 mA. Two open collector outputs monitor the system status maintenance request (MR) and system failure (SF).

  • Page 52: Installation And Parameter Settings

    Statox 560 9.3 Installation and Parameter Settings The following procedures are mandatory to be performed in order to achieve a valid data base with regards to failure rates and SFF!  The automatic self-test must be activated (see chapter 5.3.2).

  • Page 53: Failure Rates And Safe Failure Fraction

    Statox 560 9.6 Failure Rates and Safe Failure Fraction The following data have been assessed for Statox 560 system (basemodule Statox 560 inclusive sensor) in a FMEDA-Hardware-Assessment, performed by company SGS-TÜV Saar GmbH (Report # K1TK0001): Safety function 1 (SF1)

  • Page 54: Classification Of The Safety Integrity Level (Sil)

    As specified in standard IEC 61508-2:2010 table 3, with a hardware failure tolerance (HFT) = 0 and a SFF of > 90 % the Statox 560 complies with the requirements for a SIL2 rating in both safety functions (see Table 7).

  • Page 55: General Technical Data

    10 General Technical Data Product name: Statox 560 Type: 5377 Manufacturer: COMPUR Monitors GmbH & Co. KG, Weissenseestr. 101, D-81539 Munich Power supply: 24 (16-30) VDC Power consumption: max. 2.7 W (8.7 W for COCl ) at input voltage ≤ 26 VDC Operating temperature: -30°C to +60°C...

  • Page 56: Sensor-Specific Data

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 57: Ppm 562922

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 58: Statox 560 Sensor Module Cocl

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 59: Statox 560 Sensor Module Hcn 20 Ppm 562930

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 60: Statox 560 Sensor Module Hcn 100 Ppm 562934

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 61: Ppm 562910

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 62: Statox 560 Sensor Module Cl

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 63: 100 Ppm 562928

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 64: Statox 560 Sensor Module Co 300 Ppm 562916

    The values are typical values, apply for new sensors and ambient conditions of 20°C, 50% r.H. and 1013 mbar. The response times were measured with the Statox 560 calibration adapter at 30 l/h. The above list may be incomplete. The listed values are average values, they might differ from sensor to sensor.

  • Page 65: Declaration Of Conformity

    Statox 560 12 Declaration of conformity Issue 2/2017 Page 65 of 66...
  • Page 66 No licence is implied or in fact granted under the claims of any patent. Instruments are manufactured by Compur Monitors GmbH & Co. KG, Munich. The General Conditions of Supply and Service of Compur Monitors GmbH & Co. KG, Munich, are applicable. Compur Monitors GmbH & Co. KG Weißenseestraße 101...

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