Compur Statox 502 User manual

Manual
Statox 502
Control Module
Compur Monitors GmbH & Co. KG
Weissenseestrasse 101
D-81539 Münc en
P one: [phone]
Fax: [phone]
www.compur.com
[email protected]

Statox 502 Control Module
Page 2 of 40 Issue 1/2015
Content
Warning Signs ....................................................................................................................................... 3
Mounting .............................................................................................................................................. 5
Dismounting .......................................................................................................................................... 6
Connecting to power supply ................................................................................................................. 7
Start-up ................................................................................................................................................. 7
Controls ................................................................................................................................................. 9
LEDs ....................................................................................................................................................... 9
Display ................................................................................................................................................. 10
Communication bus ............................................................................................................................ 11
Electrical connections ......................................................................................................................... 11
Connecting t e external reset and analog output ................................................................... 13
Connecting t e internal relays ................................................................................................. 13
Password ............................................................................................................................................. 14
Main menu structure .......................................................................................................................... 15
Service Mode ...................................................................................................................................... 16
Selecting t e measuring program ....................................................................................................... 16
Calibration ........................................................................................................................................... 18
Reading t e bridge voltage ................................................................................................................. 20
Switc ing t e sensor power supply off............................................................................................... 21
Programming t e alarm relays ........................................................................................................... 22
Alarm relays configuration ................................................................................................................. 25
Functional test .................................................................................................................................... 26
Current output in Service Mode ......................................................................................................... 28
C anging t e operation mode – Control Module or Common Alarm Module .................................. 29
Status messages .................................................................................................................................. 32
Error messages.................................................................................................................................... 33
Control Module - Status diagram ....................................................................................................... 35
Common Alarm Module - Status diagram .......................................................................................... 35

Statox 502 Control Module
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Safety notes
Read and observe t is manual prior to installation and start-up.
T e Statox 502 Control Module is only allowed to operate under t e given ambient conditions (see
Tec nical Data). In particular, it must not be operated in potentially explosive atmosp eres!
T e Statox 502 Control Module must be operated, maintained and repaired by trained and expert
personnel only. Use only Compur Monitors original parts for repair and maintenance.
Do not connect t e module directly to mains!
Do not modify t e product. Do not use if damaged or incomplete.
W en installing t is product observe all local standards and regulations.
Disregarding of t e above points represents a danger to people and property.
Warning Signs
Potential Danger
Note on an immediate danger to people and property.
Advice
Extra information for t e proper use of t e product.
!
!

Statox 502 Control Module
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Product description
T e Statox 502 Control Module can be used in two different modes:
As a Control Module it supplies t e sensor eads for toxic or combustible gases wit energy and andles
t eir signal. It can be configured for different gases and measuring ranges. T e Statox 502 Control Module
displays t e concentration and converts it into a 4 – 20 mA signal at t e analog output. If one of t e
programmed alarm t res olds is exceeded, t e relevant LED goes on, t e relevant relay switc es and t e
relays status is communicated on t e communication bus. T e alarms can be set latc ing or non - latc ing.
Latc ing alarms can be reset by pus ing t e reset button or by an external contact.
Please note:
Sensor eads for toxic gases and oxygen (Statox 501/S and Statox 505) are protected in concept Ex i
(intrinsic safety) and must be connected via an intrinsically safe repeater, as far as t ey are intended
to be installed in a azardous area (Zone 1 or 2).
Sensor eads for combustible gases, CO
2
and VOC (Statox 501 HRC, ARE, LCIR, MCIR, Infratox, and
PID) are protected in concept Ex e (en anced safety) or Ex d (flameproof). T ey can be connected
directly to t e Control Module, even if t ey are intended to operate in Zone 1 or 2.
T e Statox 502 can also be operated as Common Alarm Module. It collects t e alarm signals (A1/A2/SF) of
up to 25 connected control modules and generates a common alarm on LEDs, relays and its analog output.
T is way you can set up a multi - c annel gas detection system. Prerequisite is t at all modules are connected
to eac ot er via bus adapter. An Error from t e Control Module or t e connected sensor eads will appear
on t e respective Control Module as well as on t e Common Alarm Module.
If power supply is provided via t e optional bus plugs, it is possible to replace t e modules during operation
wit out effort.

Statox 502 Control Module
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Getting started
T e Statox 502 control modules are designed for mounting on DIN rail TS 35. Due to t e tilted
mounting/dismounting of t e modules t e span between t e outsides of t e rail and t e wall below and
above t e Statox 502 Module must be at least 80 mm (3.15 “). Furt ermore at least 120 mm (4.72 “) must
be remain free between two rail lines.
Mounting
T e Control Module can be operated wit out bus adapter, t ey will be mounted on t e
DIN rail as s own in Figure 2. In t is case eac module must be powered separately wit
24 VDC.
1. Plug t e bus adapters toget er and snap t em on t e DIN rail as s own in Figure 1.
2. Incline t e module and move it to t e lower part of t e DIN Rail. See Figure 2.
3. Now pus t e module forward to t e rail against t e resistance of t e spring lock, until you ear it
snapping in.
Set wit 2 bus adapters, obligatory
for eac module in bus operation,
Art.# 557002
Connection set for bus adapter
(Bus plug left and rig t),
optional, Art.# 557003
DIN rail TS 35
Figure
1
: Requirements for bus operation, sample installation
Control Module, Art.# 557000
Control Module, Art.# 557000, configured as Common Alarm Module
Power supply
24 VDC
!

Statox 502 Control Module
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You can combine modules of t e Statox 502 series in any sequence. Adding or removing one module as no
impact on t e ot ers. You can save wiring effort starting wit t e power supply on t e outside and connecting
it to t e bus. Alternatively t e first module in a row can be connected to 24 ± 2 VDC, t e ot ers will be
supplied via bus. T e power rail is rated for 30 modules max. in one row. You can interconnect multiple rows
wit t e optional bus plugs (Connection set Art.# 557003, 1 set per rail is needed). For furt er information
see Accessories list chapter 12.
Dismounting
Pull t e spring lock wit a screw driver and incline t e module simultaneously, see Figure 3. T is can be done
under operating conditions.
1
2
Figure
3
:
ismounting from IN rail
Figure
2
:
Mounting to
IN rail

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Connecting to power supply
Do not connect t e module directly to mains! Do not s ort circuit terminals! Bot can
destroy t e module!
T ere are two options connecting t e 24 V C power supply, see Figure 4.
a) Via bus plug to t e communication bus
b) Directly to t e relevant Statox 502 Control Module terminal
In bot cases all subsequent modules are automatically connected to t e power supply via bus. T e terminals
are rated to take a max. diameter of 2,5 mm
2
. T e module starts operating as soon as it is connected to
power.
Start-up
In any case make sure to select t e appropriate program prior to connecting t e sensor
ead. Ot erwise t e sensor can be damaged.
Ex works t e Statox 502 is configurated to operate as Control Module. After connection to power, it performs
a self-test. It displays t e firmware version, t en for 5 seconds t e actual measuring program, t en “PLEASE
WAIT”. T e module remains in t e system fail mode until t e measuring mode as successfully been
activated. During t is process t e red LED “S” is on.
If no sensor ead is connected, an error message is generated (ERROR 2 or ERROR 5, depending on measuring
program). In t is case activate t e appropriate program as described in chapter 6.1. T en connect t e sensor
ead as described in chapter 9.
!
13
14
1
5
16
+24 V C
0 V
17
18
19
20
a)
Bus plug (left)
b) Terminal block
5
4
3
2
1
0 V
+24 V C
Figure
4
: Connecting the power supply
!

Statox 502 Control Module
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If a sensor ead as been connected and t e appropriate program as been selected, t e measuring mode
will start.
Sensor eads for combustible gases, type HRC, ARE, LC IR, MC IR and PID must be
calibrated after being connected.
Exception: A line calibration as been done by Compur.
!
Power ON
Actual firmware version is displayed 3 s.
Actual operation program is displayed 5 s.
During t is time an access to t e main menu is possible.
Figure
5
:
Start
-
up
sequence

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Product c aracteristics
Controls
T e Statox 502 as four pus buttons.
Button Function
Enter Enter.
Reset Deletes wrong entries, resets t e alarm relays, goes one step back in t e menu.
Left
*)
Navigates left in t e menu, reduces a programmed figure, c anges t e first
display line w en in t e measuring mode.
Rig t
*)
Navigates rig t in t e menu
,
increases a programmed figure, c anges t e firs
t
display line w en in t e measuring mode.
*)
In some menus a continuous pus activates t e fast mode
LEDs
T e Statox 502 as 4 status LEDs. T e function of t e individual LEDs is subsequently explained.
escription LE Function
ON Green
Power supply
:
„ON“ Power ON
„OFF“ Power voltage off or too low
A1
Yellow
Relays
1: Alarm t res old exceeded
A2
Yellow
Relays
2: Alarm t res old exceeded
S Red
Failure or service request
:
„Flas ing“ Service Mode
„ON“ System Failure
„OFF“ Measuring mode

Statox 502 Control Module
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Display
In t e measuring mode t e display s ows t e target gas, t e actual measured value and t e unit.
Example 1 (Combustible gas)
E x p l . G a s
1 0 0 % L E L
Example 2 (Toxic gas)
S O 2
1 . 3 4 p p m
In case of an over range exposure, t e full scale value is going to flas .
T e ►- or◄-Button c ange t e content of t e upper line to display t e actual program and t e end of range
value. After 20 seconds t e display goes back to t e standard content – t e target gas.
Gas Program End of range value
◄
E x p l . G a s
►◄
P r o g . x x
►◄
1 0 0 % L E L
►
2 0 % L E L 2 0 % L E L 2 0 % L E L
Gas
Measured value
Unit in % LEL (Lower Explosion Level)
Measured value
Unit in ppm (parts per million)
Gas

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Communication bus
T e bus interfaces t e 24 V-power supply and t e alarm signals from one module to t e next.
A Common Alarm Module can evaluate t e alarm signals.
Bus ports escription
0 V
Zero
-
0 V
+24 V
Positive
24 ±
2
VDC
A1
Exceeding alarm
t res old
1 se
ts t e signal on terminal A1 to
Low(0V)
A2
Exceeding alarm
t res old 2 set
s t e signal on terminal A2 to
Low(0V)
SF
A system failure sets t e signal on terminal SF to
Low
(0V)
Figure 6: Bus terminals
Electrical connections
T e Statox 502 operates at 24 ± 2 VDC. Hig er voltage or s ort circuits on t e terminals
may destroy t e module.
T e terminals are pluggable. To remove t e terminal blocks, set t e screwdriver directly over t e screws and
press t e block to t e front side.
T e terminals can take cable diameters up to 2.5 mm
2
.
!

Statox 502 Control Module
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Terminal
Contact
Function
1
Extern
al
Reset
Remote Reset
2
GND (Extern
al
Reset)
3
0
–
2
2
mA
analog output
Analog output
4
GND (0
-
2
2
mA
output
)
*
5
Sensor
voltage
-
Sensor
ead
power supply
*
6
Sense
-
Negative
s
ense
-
lead
for
5 wire operation
*
7
Sensor voltage
+
Sensor
ead
power supply
**
19
±
1 V V
oltage
output
Sensor ead power supply wit
out
repeater
*
8
Sense +
Positive Sense
-
lead for 5 wire operation
*
9
Bridge voltage
Signal
(mV)
**
10
0
–
2
2
mA
Current input
S
ignal (mA)
**
11
24
± 1
V
Voltage
o
utput
Sensor ead power supply wit repeater
***
12
GND
GND
13
24 V
Power supply
Power supply
14
Relay
SF NC
System
failure
relay
-
break contact
15
Relay
SF NO
System failure
relay
-
make contact
16
Relay
SF C
System failure
relay
-
central contact
17
GND
Power supply negative
18
Relay
A2 NC
Alarm
relay
2
–
break contact
19
Relay
A2 NO
Alarm
relay
2
–
make contact
20
Relay
A2 C
Alarm
relay
2
–
central contact
**
21
24
± 1
V Voltage output
S
ensor ead
power supply
wit repeater
22
Relay
A1 NC
Alarm
relay
1
–
break contact
23
Relay
A1 NO
Alarm
relay
1
–
make contact
24
Relay
A1 C
Alarm
relay
1
–
central contact
* Sensor eads type
- Statox 501 HRC
- Statox 501 ARE
- Statox 501 LCIR
- Statox 501 MCIR
- Statox 501 PID
** Sensor eads type:
- Statox 501/S
- Statox 501 Infratox
- Statox 505
*** Sensor eads type:
- Statox 501 Infratox
- Statox 505
Figure
7
: Pluggable terminal blocks with terminal numbers

Statox 502 Control Module
Issue 1/2015 Page 13 of 40
Connecting t e external reset and analog output
A GND-signal on terminal 1 initiates a reset just as pus ing t e RESET button.
T e analog output generates a current analog to t e actual measured value wit 4 mA corresponding to
zero and 20 mA to end of scale. A measured value ig er t an end of scale generates 22 mA.
A system failure causes a current of 0 mA, t e service mode causes a current of 2 or 4 mA (selectable).
Connecting t e internal relays
Statox 502 as t ree relays, eac equipped wit one make and one break contact. Two relays monitor
alarm t res old exceeding, one system failure.
System failure relay: T e SF-relay coil is always active and drops out in case of a system
failure or voltage drop.
T e alarm relay parameters can be set in t e main menu. T e SF-relay settings cannot be c anged.
Figure 9 s ows t e contacts:
1
2
3
4
0
–
22 mA
13
14
1
5
16
NC NO C
SF
17
18
1
9
20
NC NO C
A2
21
22
23
24
NC NO C
A1
!
Figure
8
: Connections
external
reset and analog output
Figure
9
: Relay contacts (
coil
de
-
energized)

Statox 502 Control Module
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Statox 502 main menu
Password
T e main menu is password protected. No matter if in t e measuring, t e failure or t e start mode: below
procedure gives access to t e main menu.
T e password is: 1994 (not changeable)
Figure 10: Password menu
1. Pus ◄- and ► -button toget er for 2 s.
2. Enter t e first digit wit ◄- or ►. Use t e Reset button for corrections.
3. Confirm wit Enter.
4. Continue wit t e next 3 digits t e same way.
5. After confirming t e last digit wit Enter you ave access to t e main menu, provided t e correct
password as been entered.
If message „CODE INVALID“ appears, a wrong password as been entered. Try again after two
seconds.
Press
bot
buttons for 2 s to enter
Increase or decrease value
Next digit
Correction
C ange Menu item
MEASURING MODE

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Main menu structure
After pus ing ◄- and ► -button toget er for 2 s and entering t e password, you ave access to t e main
menu. It is structured as a ring wit 9 different submenus in w ic you can set parameters or perform a
calibration. See Figure 11. Pus ing t e Reset–button always brings you back into t e measuring mode.
Figure 11: Main menu structure
Submenu escription Page
CHOOSE PROGRAM
1)
Selecting t e appropriate program for t e relevant sensor ead 16
CALIB. ROUTINE
1) 2)
Calibration wit gas 18
BRIDGE VOLTAGE
1) 2)
Monitoring t e bridge voltage in mV 20
SENSOR POWER
1) 2)
Switc t e sensor power supply off 21
OUTPUT TEST Test of t e LEDs, relays, alarms and t e analog output 26
SERVICE OUTPUT Setting of t e analog output in t e service mode 28
MODE Altering t e operation mode (Common Alarm Module or Control Module) 29
ALARM 1 RELAY Setting Alarm 1 relays parameters 23
ALARM 2 RELAY Setting Alarm 2 relays parameters 23
1)
no access if t e Statox 502 is operated as Common Alarm Module.
2)
no access if a program for t e operation of Statox 501/S, Statox 501 Infratox and Statox 505 is active.
„MENU NOT ACTIVE“ will be s own for 2 s if a menu is not accessible in t e actual mode or
program.
!
MEASURING MODE

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Page 16 of 40 Issue 1/2015
Service Mode
As soon as t e menu is entered, t e module goes into t e service mode. T e LED „S“ is flas ing, t e analog
output and t e relays are not active.
If no button is pus ed wit in 30 seconds, t e module returns to measuring mode. T is Time-out it not active
During zero adjustment and calibration in t e menu „CALIB ROUTINE“
W en switc ing t e sensor ead power supply on or off in t e menu „SENSOR POWER“
(Display s ows „SENSOR ON“ or „SENSOR OFF“)
During t e program selection in t e menu „CHOOSE PROGRAM“
During t e bridge voltage is displayed in t e menu “BRIDGE VOLTAGE”.
Statox 502 in Control Module Operation
T e sensor eads for toxic gases, oxygen or combustible gases measure t e concentration of t e target gas
in t e field. Statox 502 evaluates t e signal and displays t e value. Any alarm t res old exceeding is signaled
by an LED and t e alarm relays is activated. T e alarm is also communicated on t e bus.
Selecting t e measuring program
In t is menu t e appropriate measuring program can be selected. T e program defines t e target gas, t e
measuring range, t e concentration window for span gas and t e ex - works settings of t e relays. See an
overview of all available programs in t e program listing enclosed wit eac module.
In any case t e first step is always to select t e appropriate program. T is must be done
before t e sensor ead is connected, ot erwise t e sensor can be damaged.
If a new program is selected, t e alarm settings and relay configurations according to t e
program listing are valid and t e calibration data for t e sensor eads for combustible
gases, type HRC, ARE, LCIR and MCIR will be erased. A new calibration is necessary.
!
!

Statox 502 Control Module
Issue 1/2015 Page 17 of 40
Figure 12: Program selection diagram
1. Pus t e - button to enter t e „CHOOSE PROGRAM“ menu.
2. T e active program is s own on t e display.
3. Pus t e - button to start t e program selection
Now t e Time-Out is deactivated!
4. Select your program wit t e ◄- or ►- button. Pus and old◄- or ► for t e fast mode.
5. Confirm by pus ing t e - button.
6. T e display s ows „Store“ for 2 seconds.
7. T en t e number of t e new program is s own.
8. Confirm by pus ing t e - button to start measuring wit t e new program.
!
MEASURING MODE
Start
-
up
C ange Menu item
Active program
Select new program,
no Time-Out!
Displayed for 2 sec
New program number.
Pus ENTER to start.

Statox 502 Control Module
Page 18 of 40 Issue 1/2015
Calibration
In t is menu you can perform a calibration of sensor eads type Statox 501 HRC, ARE, LCIR, MCIR and PID
detecting combustible gases, carbon dioxide (CO
2
) and volatile organic compounds (VOC). T e test gas
concentration must be wit in t e permitted range, see program listing.
Figure 13: Calibration menu diagram
CALIB.
ROUTINE
ZERO
ADJUSTM.
000
APPLY
SPAN GAS
GAS
R
R
CALIB.
FINISHED
GAS CONC
(valu ) (unit)
FACTOR
x.yy
DONE
R
CALIBR.
FAILED
GAS
(valu ) (unit)
R
R
GAS CONC
ERROR
R
+
C ange Menu item
MEASURING MODE
Flas ing, searc ing zero point
Flas ing, turn test gas on
Displayed if zero point is adjusted
Signal is stable,
Turn test gas off
Input: gas concentration (value)
Start zeroing
Input: Reference factor (value)
Correction
Confirmation
Displayed for 2 s after
successful calibration
Actual measuring value and unit

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1. Enter t e menu „CALIB. ROUTINE“ by pus ing .
2. T e display s ows: „ZERO ADJUSTM.“
Beginning wit step 3, t e automatic Time-out is not active.
3. Pus t e - button. Display: „000“ flas ing. T e Control Module adjusts t e actual zero point.
T erefore t is procedure must be performed in clean or synt etic air.
4. „APPLY SPAN GAS“ tells you, t at t e zero point as been found and saved.
5. Make sure you ave t e appropriate test gas on and. Pus t e -button. Display: „GAS“ - flas ing.
Connect t e test gas adapter and turn on t e gas. T e module starts searc ing a stable signal.
Make sure t at sufficient test gas is available. If no test gas is applied or t ere is not
enoug test gas for t e adjustment in t e cylinder, t e module reports “ERROR 8”.
6. „CALIB. FINISHED“ tells you t at t e signal is stable – a plateau as been found. Turn off t e gas.
7. Pus t e - button.
8. In case t e display does not s ow t e concentration of t e gas cylinder, adjust it by pus ing t e
◄- or ► - button. Pus and old ◄- or ► for speed mode. Entering t e concentration must be
carried out in t e respective display unit, e.g. combustible gases are s own in % LEL. See t e last
column of t e program listing . Confirm wit Enter.
9. If needed you can enter a reference factor for t e Statox 501 HRC, ARE and PID sensor eads.
Program it wit t e ◄- or ►- button. If you need to correct your entry, pus „Reset“. How to use
response factors is described in t e relevant sensor ead manual. If no factor needs to be
programmed, leave t e value at 1.00.
10. Close t e menu wit Enter.
a) Display: „GAS CONC ERROR“: (only possible if t e response factor is not 1). T is tells you t at t e
product (response factor * span gas concentration) is not wit in t e permitted range for span
gas. Confirm wit . T is brings you back into t e main menu. C eck t e input for reference
factor and gas concentration and accordingly use a test gas wit suitable concentration for
recalibration.
b) Display: „CALIBR. FAILE “:
Calibration failed, because t e calculated plateau signal is too low. Confirm wit -button. T is
brings you back into t e main menu. C eck t e values for response factor and gas concentration.
Repeat t e calibration wit a test gas wit ig er concentration or replace t e sensor.
c) Display „ ONE“:
T e calibration was successful. After 2 s t e display c anges.
!
!

Statox 502 Control Module
Page 20 of 40 Issue 1/2015
11. T e display will now s ow t e actual measured value wit unit.
In order to avoid unrequested alarms make sure t e signal created by t e test gas as
dropped below t e alarm t res old prior to returning into t e measuring mode.
12. Confirm wit to return to t e main menu.
13. Return into t e measuring mode by pus ing Reset.
If t e calibration as not been completed successfully (ERROR 8, CALIBR. FAILED or GAS
CONC ERROR), t e module will continue wit t e most recent valid data. T e display s ows
alternating „CALIB. FAILED“ and t e measured value. A new calibration s ould be done as
soon as possible.
Reading t e bridge voltage
Active in t e programs for Statox 501 HRC, ARE, LCIR, MCIR, PID sensor eads.
T e current bridge voltage of t e sensor can be displayed.
Figure 14: Bridge voltage menu diagram
BRIDGE
VOLTAGE
(-) xxx
mV
R
R
+
!
!
MEASURING MODE
C ange Menu item
Actual bridge voltage,
no Time-Out