Compur Monitors Statox 560 User manual

Operators Manual
Statox 560

Statox 560
Page 2 of 66 Issue 2/2017
Content
1Safety Advice............................................................................................................................... 4
2Product description..................................................................................................................... 5
3Installation and Connection......................................................................................................... 6
3.1 Maximum distance to the power supply.............................................................................................. 6
3.2 Mounting .............................................................................................................................................. 7
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........................................................................................................................ 14
4Product characteristics.............................................................................................................. 15
4.1Housing ............................................................................................................................................... 15
4.2 Keys..................................................................................................................................................... 15
4.3 LEDs..................................................................................................................................................... 16
4.4 Display................................................................................................................................................. 16
4.5 Sensor module.................................................................................................................................... 17
5Getting started and menu navigation........................................................................................ 17
5.1 Start - Up, Connecting the Sensor Module......................................................................................... 18
5.2 Menus ................................................................................................................................................. 21
5.2.1 General ..................................................................................................................................... 21
5.2.2 Accessing the Service Menu..................................................................................................... 22
5.3 Menu overview................................................................................................................................... 22
5.3.1 Prooftest................................................................................................................................... 24
5.3.2 Self-test..................................................................................................................................... 25
5.3.2.1 Submneu Self-Test - Info................................................................................................ 26
5.3.2.2 Submenu Self-test - Manual Start.................................................................................. 27
5.3.2.3 Submenu Self-test –Start time ..................................................................................... 28
5.3.2.4 Submenu Self-test - Monitoring..................................................................................... 29
5.3.3 Calibration ................................................................................................................................ 30
5.3.4 Change Sensor –Sensor Module / Sensor / Generator Cell Replacement .............................. 33
5.3.4.1 Sensor module replacement .......................................................................................... 33
5.3.4.2 Sensor and Generator Cell replacement:....................................................................... 34
5.3.5 Errors Info................................................................................................................................. 37
5.3.6 Alarm History............................................................................................................................ 37
5.3.7 Sensor Info................................................................................................................................ 38
5.3.8 Temperature............................................................................................................................. 39
5.3.9 Firmware................................................................................................................................... 39
5.3.10Alarm Relays............................................................................................................................. 39
5.3.11Real Time Clock......................................................................................................................... 41
5.3.12Service Output.......................................................................................................................... 42
5.3.13Function Test ............................................................................................................................ 43
5.3.14Maintenance Request .............................................................................................................. 45
6System Status and Error Messages............................................................................................ 46
6.1 System Status...................................................................................................................................... 46
6.2 Error messages.................................................................................................................................... 47
7Maintenance and Cleaning........................................................................................................ 49

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7.1 Routine treatment...............................................................................................................................49
7.2 Replacing the pump.............................................................................................................................49
8Accessories and spare parts.......................................................................................................50
9Functional Safety .......................................................................................................................51
9.1 Safety Functions ..................................................................................................................................51
9.2 Diagnostic Time and Measuring Cycle.................................................................................................51
9.3 Installation and Parameter Settings....................................................................................................52
9.4 Schedule Maintenance........................................................................................................................52
9.5 Repair and Spare Parts ........................................................................................................................52
9.6 Failure Rates and Safe Failure Fraction ...............................................................................................53
9.7 Average Probability of Failure on Demand .........................................................................................53
9.8 Classification of the Safety Integrity Level (SIL)...................................................................................54
9.9 Livetime ...............................................................................................................................................54
10 General Technical Data..............................................................................................................55
11 Sensor-specific data...................................................................................................................56
11.1 Statox 560 Sensor Module COCl20.5 ppm 562920 ...........................................................................56
11.2 Statox 560 Sensor Module COCl21 ppm 562922 ...............................................................................57
11.3 Statox 560 Sensor Module COCl250 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 Cl25 ppm 562910 ...................................................................................61
11.7 Statox 560 Sensor Module Cl210 ppm 562912 .................................................................................62
11.8 Statox 560 Sensor Module H2S 100 ppm 562928...............................................................................63
11.9 Statox 560 Sensor Module CO 300 ppm 562916................................................................................64
12 Declaration of conformity..........................................................................................................65

Statox 560
Page 4 of 66 Issue 2/2017
1Safety 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.
Installation must be performed by trained and authorized personnel. Only original Compur
Monitors parts may be used.
The Statox 560 must not be connected to mains! The supply voltage is 24 (16-30) VDC.
All outputs of the Statox 560 may only be operated with 30 VDC.
Damaged or modified sensor heads must not be used.
The Ex d housing must not be opened!
When operated in hazardous atmosphere, the sensor head must be connected to the exLink
counterpart or to a certified connection box.
Disregarding these recommendations may compromise the protection and result in a danger for
personnel and material.
These signs mark important information:
DANGER
Indicates direct danger for man and material.
HINT
Important Information.
!
!

Statox 560
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2Product 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. It is a detector for toxic gases and can be operated outdoors or
indoors. Extensive self –diagnosis algorithms and the relevant hardware comply with the requirements for
SIL 2 applications.
The daily self-test with internally generated test gas guaranties maximum safety and availability.
The Statox 560 sensor head can be operated by magnetic pin through the window of the flame proof
housing. The actual concentration is shown on the display and will be transmitted as 4 –20 mA signal. The
system status (alarms, system failure, and maintenance request) is shown on the LEDs and signalized via
the current output. External alarm devices can be connected to 4 open drain outputs via relays.
Picture 1: Sensor head Statox 560
4
11
10
9
8
3
1
5
7
6
1 Protective cap
2 Protection cylinder
3 Ex i Part
4 Grounding terminal
5 Control panel
6 LCD
7 LEDs
8 Blind plug
9 Cable tail or eXLink-plug
10 Ex d Housing
11 Drill holes for fastening
12 Magnetic pin
2
12

Statox 560
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3Installation 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. These requirements are based on 24 VDC power
supply and optimum contact resistance.
Diameter or
AWG-No.
Maximum distance to power supply [m]
COCl2
HCN, H2S, Cl2, CO
24-AWG
96
314
0,25 mm²
107
351
0,5 mm²
214
700
20-AWG
242
793
19-AWG
306
1000
0,75 mm²
321
1049
18-AWG
385
1261
1 mm²
427
1399
16-AWG
613
2006
1,5 mm²
627
2051
14-AWG
975
3190
2,5 mm²
1044
3418
Table 1: Maximum distance to power supply depending on the gas to be measured at 20 °C
Observe these maximum cable length for error-free operation!
!

Statox 560
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3.2 Mounting
Install the Statox 560 close to a potential leakage or between a potential leakage and a workplace. In
particular observe the following parameters:
Air stream (wind, ventilation, thermal effects)
Properties of the target gas (specific weight)
Protection from direct sunlight, splash water, dust, dirt etc.
Easy accessibility for maintenance and programming
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.
Compur Monitors offers an Ex e rated terminal box (art. # 562988) made of varnished cast aluminum.
It has
10 numbered contacts for wiring with Ø 2.5 mm²
an outside grounding terminal for wire Ø 4 mm²
EMC –proof cable glands for cables 6-13 mm
Outer dimensions 122 x 120 x 80
wall mounting with 4 screws M6

Statox 560
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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!
!
Ø 8,3

Statox 560
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3.3 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.
Picture 3: Statox 560 cable tail connection
Caution:
A. Connect the grounding contact to the ground of the building, using a cable diameter ≥ 6 mm². Check
your installation for proper grounding.
B. Remove the protective tube from the cable shield and insert the cable through the EMC –proof cable
gland. Remark: the cable shield is not connected to the sensor head housing!
C. Connect the cores in the sequence of their numbers to the terminals, the white core to terminal 10. All
cores must be connected, even if you do not use them all.
A
B
D
C
E
!

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Page 10 of 66 Issue 2/2017
D. Connect the grounding contact of the junction box to the ground of the building. Use a cable with
≥4 mm² diameter. Check for proper grounding.
E. The number of outgoing cable glands depends on your application. In order to avoid ground loops,
ground the cable shield only on one side.
Do not try to remove the cable tail from the sensor head. It will destroy it!
Never leave lose cable ends in the terminal box!
Proper grounding is essential for error–free operation!
Table 2: Connecting the cable tail
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.
Wire
Function
Description
1
+24 VDC
+ 24 V power supply (16-30 VDC)
2
0 VDC
Power supply ground
3
I_OUT+
0-22 mA Current output
4
I_OUT-
Current output ground
5
Remote Self-test
Remote self–test trigger
6
GND_R
Common ground for all relays
7
Maintenance Request
Relay output maintenance request (open drain)
8
System Failure
Relay output System failure (open drain)
9
A2
Relay output Alarm 2 (open drain)
wt
A1
Relay output Alarm 1 (open drain)
!

Statox 560
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Picture 4: Connection of the eXLink
Please observe points A to E in chapter 3.3, they apply to this application method, too. It is not mandatory
to connect all contacts on the field side.
Do not connect the cable shield to the coupling!
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.
Loosening it will destroy Ex d rating of the housing!
!
A
D
B
C
E

Statox 560
Page 12 of 66 Issue 2/2017
Pin assignment:
Table 3: Pin assignment Statox 560 eXLink-plug
Contact
Function
Description
1
+24 VDC
+ 24 V Power supply (16-30 VDC)
2
0 VDC
Power supply ground
3
I_OUT+
0-22 mA Current output
4
I_OUT-
Current output ground
5
Remote Self-test
Remote self-test trigger
6
GND_R
Common ground for relays
7
Maintenance Request
Relay maintenance request (open drain)
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!
Make sure not to exceed the maximum cable length (see chapter 3.1).
Use two separate wires to connect the ground on pin 2 and the ground on pin 4 to the Statox 502
Control Module.
A Statox 502 Control Module can be programmed to operate as a common alarm module.
Connect the cable shield to one side only to avoid ground loops!
1
2
3
6
4
5
7

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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. 5 can be used as remote self-test trigger. It has the same function as the automatic or manually
initiated self-test started with the magnetic pin. Therefore the wire number 5 must be connected to ground
via a non - latching pushbutton (see Picture 6). By pressing the button, the signal will be connected to ground
and the self-test is starting.
Output 0-22mA
GND
Power +24V
Power 0V
Read and observe point
A to E in chapter 3.3!
D
A
B
C
E
!

Statox 560
Page 14 of 66 Issue 2/2017
3.7 Connection to the Open-Drain switching outputs
The four switching outputs are Open-Drain-signals. The output can be connected to external relays
operated with max. 30 V DC with a max. current of 2.5 A. Connecting the alarm relays is optional.
Pin 6 - GND_R is the common ground for all alarm relays.
Picture 7: How to connect an alarm relay
It is mandatory to connect a freewheel diode to the relay (see Picture 7 - D).
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.
!

Statox 560
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4Product 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
and certified personnel of Compur Monitors representatives!
No warranty on sensor heads which have been opened by unauthorized personnel!
The lower part of the Statox 560 (stainless steel) is intrinsically safe. It can be opened without hot-work
permit and without disconnecting the sensor head power supply. In order to change the sensor module,
unscrew the protection cylinder counter clockwise (see Chapter 5.3.4).
4.2 Keys
Statox 560 can be operated through the window with a magnetic pin. The magnetic pin activates hall
sensors inside the sensor head. Just hold the slim part of the pin next to the key. The individual keys have
the following functions:
Keys
Function
Enter
Confirm entries.
Reset
Delete false settings. Step back to the recent menu. Reset alarms.
Left
Navigates left in the menu, reduces a set value, and accesses the service menu.
Right
Navigates right in the menu, increases a set value, and accesses the info - menu.
!

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Page 16 of 66 Issue 2/2017
4.3 LEDs
4 LEDs signalize the actual system status of Statox 560:
Name
Color
Function
ON
Green
Power supply:
„ON“ : Power is on.
„Off“:Power is too low or off.
A1
Yellow
Alarm relay A1 is activated, alarm threshold A1 has been exceeded.
A2
Yellow
Alarm relay A2 is activated, alarm threshold A2 has been exceeded.
S
Red
System status:
„OFF“: System operating.
„ON“: System failure or system inactive.
„Flashing steadily“: Service mode.
„Periodic double - flash“: Maintenance request.
4.4 Display
The display is lighted. It shows the target gas, the concentration and the unit. If the concentration is out of
range, the full-scale value is flashing.
Picture 8: Statox 560 Front view
Gas
Measured value in
ppm (parts per million)
COCl2
0.84 ppm

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4.5 Sensor module
The plug-and-play sensor module reduces the maintenance labor in the field to a minimum. After removing
the protection cylinder, you can unplug the sensor module. It can be removed without deactivating the
sensor head (see Chapter 5.3.4). After inserting a new sensor module, it communicates all parameters
inclusive calibration data to the sensor head.
The sensor module includes the specific sensor and a generator cell, producing the appropriate gas for the
self-test. To change the individual components you have to open the module.
Picture 9: Sensor module
The sensor module parts are sensitive to electrostatic discharge. Observe the handling
precautions for ESD sensitive material. Electrostatic discharge may destroy the sensor
memory!
5Getting 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.
In case there is no sensor module connected, the display will alternatingly show „No Sensor“. You may now
connect the sensor module. Schematics of the start-up see Picture 11.
generator connection
(only COCl2)
pump intake
Sensor plug (without
short circuit bridge)
!
Drill holes for
guiding pins
Top screw

Statox 560
Page 18 of 66 Issue 2/2017
5.1 Start - Up, Connecting the Sensor Module
1. Remove the yellow protective cap and unscrew counterclockwise the protection stainless steel
cylinder. Keep the protective cap! It might be useful to protect the sensor head from pollution
when leaving it without sensor module.
2. Take the Sensor Module out of the package. If there is a short circuit bridge (applicable for 2
electrode sensors) remove it. Check for eventual damage!
3. Insert the guiding pins into the relevant drill holes to connect the sensor module by pushing it
carefully upward (see Picture 10).
Picture 10: Connecting the sensor module
4. Now fingertight fasten the protective cylinder. The sealing ring must be clean!
5. The sensor head will now detect the sensor module. The display shows „Loading Parameter“, while
all operation –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 . 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. Now
you can use the desired sensor module.
7. During the warm-up the display shows alternatingly the menus gas/measuring range/parameter
version and serial number/best before date (week/year). This procedure can take some minutes,
especially with 3-electrode-sensors.
Sealing ring

Statox 560
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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:
Set the real time clock (see chapter 5.3.11)
Set the self-test parameters (see chapter 0)
Set the alarm relays (see Chapter 5.3.10)
Change the sensor module only in the menu Change Sensor, see Chapter 5.3.4! In order to
avoid a data loss in the sensor memory.
!
!

Statox 560
Page 20 of 66 Issue 2/2017
Picture 11: Schematics warm-up
yes
yes
Measuring mode
Firmware 01.02
2016-06-16 10:33
Sensor
detected?
NO
SENSOR
Loading
Parameter
COCL2 50,0 ppm
Version 02.3.01
Sensor No. 19718
b. b.: w 3/2016
Warm-up
Please wait
Please wait
Warm up
finished?
Power On
no
Change of sensor
type! → OK
no
remove sensor
module
Change Sensor
Replace (flashing)
connect sensor
module