Compur Monitors Statox 501 User manual

Statox 501 PID Sensor Head
no ATEX

2
Statox 501 PID Sensor Head
Operation Instructions
1SAFETY ADVICE 3
2INTRODUCTION 3
2.1 Measuring principle 3
2.2 Operation mode 3
2.3 Different models 4
3DRILLING PLAN, DIMENSIONS, CONSTRUCTION, SCOPE OF DELIVERY 4
4INSTALLATION AND ELECTRICAL CONNECTION 5
4.1 Caution 5
4.2 Installation 5
4.3 Electrical connection 5
5START UP AND MEASURING MODE 6
6CALIBRATION WITH GAS 7
7TROUBLESHOOTING 8
8MAINTENANCE / REPLACEMENT OF CONSUMABLES 8
8.1 Lamp cleaning / replacement of consumables 9
8.1.1 Removing the sensor 9
8.1.2 Polishing the lamp 10
8.1.3 Electrode stack and lamp replacement 10
8.1.4 Assembly and installation of the sensor 10
8.2 Sensor replacement 11
8.3 Replacing the filter membrane inside the sensor protection cap 11
8.4 Maintenance and cleaning of the sensor head housing 11
9SPARE PARTS AND ACCESSORIES 12
10 TECHNICAL DATA 12
11 DECLARATION OF CONFORMITY 13

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1 Safety advice
The following safety guidelines must be observed in particular:
Read and observe this manual.
This Statox 501 PID version is not safe to be used in explosive areas!
Please observe precautions for handling electrostatic sensitive devices during sensor replacement.
The interface is exclusively designed to operate MiniPID sensors with unfilled solder well. For details
see chapter 10: Technical Data.
The retaining nut must be fastened at all time. It may only be removed for sensor replacement or
maintenance.
While connecting the sensor head to the signal cable, power must be off.
The sensor head may only be operated within the specified environmental conditions.
Damaged or not tightly closed housings may cause malfunction or loss of accuracy.
2 Introduction
The intended use is the measurement of VOC (Volatile Organic Compounds).
2.1 Measuring principle
The target gas passes a membrane and enters the measuring chamber, where it is ionized by a high –
energy UV lamp. This produces ions, which are discharged at the electrodes. The discharge current
produced depends on the number of molecules entering, i.e. the concentration.
A PID will detect all substances with an ionization potential smaller than < 10.6 eV. Non detectable, and
also not interfering are O2, N2, CO, CO2and CH4. Very high humidity will quench the signal.
For calibration use Isobutene as reference gas (see chapter 6).
2.2 Operation mode
The Statox 501 PID sensor head operates in the diffusion mode.
If you want to operate the Statox 501 PID in the flow mode, please contact your Compur Monitors expert.

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2.3 Different models
The parameters of the Statox 501 PID interface are set ex works to the requirements of your application.
Target gas and measuring range are hardware programmed and noted on the type plate.
The sensor type is labeled on the sensor:
PID-A1 or MP3SM6FC = ppm Sensor, PID-AH or MP3SB6FC = ppb Sensor.
It is important to know which sensor type is in use, in case you need to order spare parts or consumables
(see chapter 9).
3 Drilling plan, dimensions, construction, scope of delivery
1 Grounding contact
2 Mounting drill holes for Ф4 mm bolts
3 Aluminum housing
4 Cable gland for cable Ф6-11 mm
5 Magnetic pin
6 Blind plug
7 Plastic tool to open sensor
8 Sensor protection cap with gas access through filter membrane
9 Nut holding the protection cap
10 Hall sensor, contact area for the magnetic pin
11 LED
12 Interface
13 2 bridges for 3-wire operation (to be installed on the Statox Control Module)
Function of the blind plug:
The thinner end is a magnetic pin, triggering the internal hall sensor. Hold it close to the contact area
on the interface housing to enter the calibration routine.
The bigger end can be used to seal the sensor head, once the sensor has been removed for service.
Dimensions in mm
1
3
4
5
6
7
9
8
2
10
11
12
13

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4 Installation and electrical connection
4.1 Caution
The sensor head must be protected from mechanical damage and from ambient conditions outside its
specifications. Mount it to the wall at a location where it is easily accessible for service.
Place the sensor head close to potential gas leaks considering the specific gravity of the target gas, when
selecting the installation level.
Position: gas access downwards (+ / - 15° ).
Use a shielded cable to transmit the signal to the Statox 501 control module. The sensor head housing
must be grounded. Observe local regulations for electrical installations.
4.2 Installation
The housing has two pocket holes for wall installation. You need two screws Ø 4mm.
4.3 Electrical connection
Recommended cable: 3 x or 5 x 0,75 mm², with dense-mashed shield. Outer diameter ca. 6 mm
(e.g. type Oelflex 415 CP3 X 0.75).
The Statox 501 PID sensor head can be operated in the 3–wire or 5–wire mode.
Select 3-wire mode if the electrical resistance of the cable loop is < 5 Ω.
Select 5-wire mode if the electrical resistance of the cable loop is ≥ 5 Ω. In this mode the two additional
„sense“ leads measure the voltage directly on the sensor head and the control module compensates for
the voltage drop in the cable.
If there are high potential differences in your plant, ground the shield only on the Control Module side.
The Statox 501 PID needs a Statox 502 or 503 Control Module for operation. Select the appropriate
program prior to connecting the sensor head (if the couple sensor head / control module does not
have an ex-works calibration).
For this purpose, observe the manual of the control module and the corresponding program
listing (programs 80 - 83).
Selecting the wrong program might destroy the sensor or cause malfunction!
If you have purchased an ex-works calibration sensor head plus control module, the devices are
labeled as calibrated pairwise. In this case do not change the program of the control module!
Otherwise, the calibration parameters will be lost! Ex-works-calibrated components do have
labels with all relevant information on them.
If you want to form group alarms, you can operate a Statox 502/503 control module in the common alarm
mode. For more information read the manual of the control module.
Connecting the interface:
Terminal
Wire
Assignment
4 or 5
blue
Power supply -
3
black
Signal
1 or 2
red
Power supply +

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5-wire mode 3-wire mode
Electrical connections for Statox 501 PID sensor heads to Statox 502/503 control modules.
Faulty connection may destroy the interface!
5 Start up and measuring mode
When connected to power, the LED is flashing green / red alternatingly.
Steady green light indicates the sensor head is in the measuring mode.
After start up, allow 30 min warm up time. Then perform a calibration. The calibration can be
neglected if an ex-works calibration sensor head and its control module has been purchased. In this
case the devices are labeled pairwise.
To enter or exit the calibration mode hold the magnetic pin on to the contact area on the type plate.
After any change of program or change of control module a calibration is mandatory.
Different modes of operation:
LED
mode
Control Module display
activity
LED flashing green /
red alternatingly
initial phase
First PLEASE WAIT,
then actual concentration
---
green
measuring mode
actual concentration
---
flashing green
calibration mode
see Control Module
manual
calibrate or return to
measuring mode
short red flash, then off
Error: sensor
defective or missing
Er 5
see chapter 7
off
Error: power supply
voltage too low
Er 5
see chapter 7
LED flashing green /
red alternatingly longer
than 1 minute
Error: wrong program
or voltage too low
actual concentration
check program and wiring
Netzteil
Statox 502/503
Statox 502/503

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6 Calibration with gas
A calibration can only be performed together with a Statox 502 or 503 Control Module (linecalibration).
After an ex-works linecalibration, the mated devices are labeled pairwise.
A calibration is required
after installation (other than ex-works line calibration)
after replacement of the control module
after changing the program
after sensor replacement
in time intervals as required by local regulations.
Before calibrating, allow 30 min warm up time.
Calibration to liquid substances in the field is labor intensive and prone to error. Use Isobutene as
reference gas and apply the response factors (noted on the type plate) provided by Compur Monitors.
The tools required for calibration are: span gas in appropriate concentration, a regulator and a gas
adapter.
The interface will accept set points between 10 and 100 % of the end of scale value.
To achieve best accuracy Compur Monitors recommends to calibrate at the desired alarm threshold
value. Calculate the most suitable span gas concentration with this formula:
Procedure:
Hold the magnetic pin on to the contact area to start the calibration routine. The green LED will start
flashing. If there is no further activity, the sensor head will automatically return to the measuring mode
after 30 minutes.
Enter the menu “CALIB. ROUTINE” on the Control Module. Adjust zero.
Connect the gas tube to one of the fittings of the gas adapter. If you want to avoid gas emissions, you
may connect an active carbon filter to the outlet. (Art.no. 806 488) Do not bend or twist the tube to
avoid overpressure in the gas adapter.
As soon as the Control Module displays „APPLY SPAN GAS“, connect the gas adapter to the sensor
and open the valve. Press „Enter“. The recommend flow is 20 l/h (300 ml/min).
As soon as „CALIB. FINISHED“ is displayed, press „Enter“ again.
Now enter the product of span gas concentration multiplied by the response factor.
In case the sensor signal is too low, you will get the message „GAS CONC ERROR“or “CALIBR.
FAILED” on the Control Module. Proceed as described in the next chapter.
Remove the gas adapter and switch the gas off.
Leave the calibration menu on the Control Module.
Touch the contact area on the PID with the magnetic pin to enter the measuring mode. The LED
should be green then.
Alarm threshold
c Isobutene =
Response factor
Example: Measuring range 0 - 1000 ppm methyl methacrylate, Response factor = 1,6
minimal Isobutene concentration: 100 ppm / 1,6 = 62,5 ppm Isobutene
maximum Isobutene concentration : 1000 ppm / 1,6 = 625 ppm Isobutene
Example: Calibration to methyl methacrylate with 100 ppm Isobutene.
You have to enter 100 ppm * 1,6 = 160 (The response factor of methyl methacrylate is 1,6)

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7 Troubleshooting
The LED going off and the Control Module displaying Err 5, may have the following reasons:
Sensor missing
Incorrect wiring
The voltage at the terminals 1/2 and 4/5 is < 4.6 V. Check the program.
Sensor defective
Interface defective.
If calibration is not possible (Control Module displays “GAS CONC ERROR“ or “CALIBR. FAILED” after
entering the gas concentration), follow this procedure:
Check if there is enough gas in the cylinder. Is the regulator open? Is the tube free?
Check the filter membrane for proper gas access.
Polish the sensor lamp (see 8.1).
Replace the lamp (see 8.1).
Replace the electrode pack (see 8.1).
Check the voltage at the terminals 1/2 and 4/5. It must be > 4.6 V.
Replace the sensor (see 8.2).
If all this does not help, call Compur Monitors technical service.
8 Maintenance / Replacement of consumables
A PID sensor will gradually loose sensitivity over time. This process depends on the ambient conditions
and the target gas. Therefore, regular calibration, lamp cleaning and replacement of consumables is
necessary to guaranty accurate measurement. Compur Monitors recommends to hold stock of
consumables.
Terms of warranty
PID sensor electronics: 12 months after delivery date. The delivery date is declared as “QC week/year”
on the sensor label.
No warranty on consumables such as sensor lamps and electrodes.
Observe the general precautions for handling electrostatic voltage sensitive electronic
components and breakable glass.
It is safe to install and remove the sensor while the sensor head is connected to the control module.

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8.1 Lamp cleaning / replacement of consumables
8.1.1 Removing the sensor
Open the retaining nut counter clockwise until you can
remove it, by pulling it downwards.
Unplug the sensor pulling it downwards. Work on the sensor
should be performed in a clean environment.
Place the sensor on clean soft cloth, pins upward.
Insert the plastic pliers into the two ports on the
sensor and press until you hear a click.
Carefully lift the sensor. If the electrode stack and
lamp do not come loose easily, apply the pliers
again.
Protect the sensor slot by re-installing the retaining nut
(see chapter 8.1.4) and closing it with the blind plug.

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8.1.2 Polishing the lamp
8.1.3 Electrode stack and lamp replacement
Make sure to select the correct spare parts (ppm- or ppb-version)!
The ppb - electrode stack is white, the ppm - electrode stack is blue.
Do not touch the front side of the lamp or the metallic parts of the electrodes.
8.1.4 Assembly and installation of the sensor
Pull the lamp carefully out of the electrode stack.
Never touch its polished front side.
Polish the front side with a cotton swap and the
polishing powder. Apply tender pressure until you
hear a silent squeak. Remove loose polish
particles with a fresh swap until the lamp front is
absolutely clean.
Push the lamp slightly rotating into the O - ring up
to the stop.
The lamp must flush with the electrode.
Legen Sie den Elektrodenstapel mit Lampe auf
den Tisch und setzen Sie den Sensor lagerichtig
von oben auf.
Drücken Sie den Sensor vorsichtig nach unten,
bis die Federn einrasten. Sensor anheben und
festen und bündigen Sitz des Elektrodenstapels
prüfen.
Stecken Sie den Sensor wieder in das Interface.
Place the electrode stack with the lamps front
side downwards on the table. Now place the
sensor on it. Make sure the two parts match in
correct position.
Push the sensor downwards until the springs
snap in.
Check for tight and flushing assembly.
The sensor is now ready to be connected to the
interface.

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To restart the sensor head, push the „Enter“ - button on the Control Module.
After any opening of the sensor, a calibration is mandatory.
8.2 Sensor replacement
Observe the general precautions for handling electrostatic voltage sensitive electronic
components!
Make sure to select the correct spare parts. The sensor article codes are marked on its type plate:
PID-A1 or MP3SM6FC = ppm sensor, PID-AH or MP3SB6FC = ppb sensor.
Observe chapter 8.1.1 and 8.1.4 for removing or installing the sensor.
8.3 Replacing the filter membrane inside the sensor protection cap
The gas access opening is protected from dust and humidity intrusion by a Teflon membrane.
Whenever the membrane has been damaged or polluted, it must be replaced. (Art. No. 511206).
Remove the clamping ring using a small screw driver. Install a new membrane and clamp ring by
pressing both in their position.
8.4 Maintenance and cleaning of the sensor head housing
Clean the sensor head with a damp cloth. Do not use detergents or solvents. No high pressure
cleaning!
Perform visual inspections on a regular basis. Check the gas access for pollution and damage.
Installation of the sensor protection cap: The O-Rings
(1+2) must be properly positioned in their seats on the
sensor protection cap.
Take the sensor protection cap in one hand, make the
positioning pin of the interface match its rest in the cap,
press it upwards and tighten the nut hand tight.
Incorrect positioning may affect the sensors protection
from dirt and humidity!
1
2
1

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9 Spare parts and accessories
Description
Article number
STATOX 501 Sensor head PID flow adapter
511101
STATOX 501 Spare sensor PID ppm
511214
STATOX 501 Spare sensor PID ppb
511215
STATOX 501 Sensor head PID interface (no Atex)
511001
STATOX 501 Sensor head PID sensor blind plug
511205
STATOX 501 Sensor head PID filter set
511206
STATOX 501 Sensor PID spare lamp
511218
STATOX 501 Sensor PID spare electrodes ppm
511223
STATOX 501 Sensor PID spare electrodes ppb
511224
STATOX 501 Sensor PID polishing set
511207
Statox 502 Control Module
557000
Statox 503 Control Module
555500
Span gas 58l Isobutene 10 ppm in air
556508
Span gas 58l Isobutene 100 ppm in air
569406
Calgas 58l regulator 715 flow = 300 ml/min
556637
Gas tube 1 m
556710
Active carbon filter
806488
10 Technical data
Instrument: Statox 501 PID Sensor head no Atex
Type: 5366
Manufacturer: COMPUR Monitors GmbH & Co. KG, D-81539 München
Power supply: 5.2 V DC
Max. current: 50 mA, start - up current 150 mA for max. 0,3 s
Operation temperature: -30° - +60°C
Protection class: min. IP54
Humidity: 0-95 %, non condensing
Accuracy at the calibration concentration: ± 10 % at constant temperature and humidity
Use exclusively the following MiniPID sensors:
MiniPID Reg. MP3SM6FC
MiniPID Reg. MP3SB6FC
MiniPID-A1
MiniPID-AH
This solder well must be free from solder !
Signal interferences
Pressure: Ambient pressure variations are neglectible. In the flow mode calibration under flow
conditions is recommended.
Temperature: Variations within specifications are neglectible.
Absolute humidity: Humidity itself is not detected, but it may quench the signal.
Gas concentration: Very high concentrations may partly absorb ionization energy and thus also
quench the signal. Calibration at the alarm threshold will guaranty maximum accuracy.

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11 Declaration of Conformity

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Specifications are subject to change without notice, and are provided only for comparison of products. The conditions under which
our products are used, are beyond our control. Therefore, the user must fully test our products and / or information to determine
suitability for any intended use, application, condition or situation. All information is given without warranty or guarantee. Compur
Monitors disclaims any liability, negligence or otherwise, incurred in connection with the use of the products and information. Any
statement or recommendation not contained herein is unauthorized and shall not bind Compur Monitors. Nothing herein shall be
construed as a recommendation to use any product in conflict with patents covering any material or device or its use. 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
D-81539 München
Tel.: ++49/89/ 6 20 38 268
Fax : ++49/89/ 6 20 38 184
http://www.compur.com
E-Mail: [e-mail]
5366 060 998 07 04 / 04.18 511041