Compur Statox 501 Administratorhandbuch

Statox 501 PID Sensor Head

Operation Instructions

1SAFETY ADVICE 3

2INTRODUCTION 4

2.1 Measuring principle 4

2.2 Operation mode 4

2.3 Different models 4

3DRILLING PLAN, DIMENSIONS, CONSTRUCTION, SCOPE OF DELIVERY 5

4INSTALLATION AND ELECTRICAL CONNECTION 6

4.1 Caution 6

4.2 Installation 6

4.3 Electrical connection 6

5START UP AND MEASURING MODE 7

6CALIBRATION WITH GAS 8

7TROUBLESHOOTING 9

8MAINTENANCE / REPLACEMENT OF CONSUMABLES 9

8.1 Lamp cleaning / replacement of consumables 10

8.1.1 Removing the sensor 10

8.1.2 Polishing the lamp 11

8.1.3 Elektrode stack and lamp replacement 11

8.1.4 Assembly and installation of the sensor 11

8.2 Sensor replacement 12

8.3 Replacing the filter membrane inside the sensor protection cap 12

8.4 Maintenance and cleaning of the sensor head housing 12

9SPARE PARTS AND ACCESSORIES 13

10 TECHNICAL DATA 14

11 DECLARATION OF CONFORMITY 15

1 Safety advice

The interface is an explosion-proof device certified for group II category 2. Its intended use is to operate a

Photo - Ionisation - Sensor (PID) for the detection of volatile organic compounds (VOC).

Designed to provide increased safety it is applicable in zone 1 and zone 2.

The following safety guidelines must be followed in particular:

• Observe the safety guidelines applicable for electronic components sensitive to electrostatic voltage.

• The retaining nut must be tightened at all time. It may only be removed for sensor replacement or

maintenance. Do not operate the sensor head without sensor or retaining nut.

• The interface has been designed to operate exclusively certified MiniPID sensors (Baseefa

07ATEX0060U) with unfilled solder well. For details see chapter 10:Technical Data.

• The interface may only be installed by trained and authorised personnel. The protection class

Ex e [ib] mb IIC T4 Gb must not be compromised.

• When connecting cables in the junction box of the sensor head housing, the power supply must be

disconnected.

• The interface may be connected to housings rated increased safety “Ex e“. Installation must comply

with EN 60079-7. Cable and its termination must be protected from mechanical damage and must

stay within the temperature specifications (80°C) of the cable.

• The interface and the sensor must be operated within ambient conditions as specified in the

technical data. Operating the sensor head outside the specified ambient conditions might damage

the sensor or interface, lead to malfunction and compromise safety.

Avoid:

- Temperatures > + 60°C

- Temperatures < - 30°C

- Wetness and dust. Maintain ingress protection IP54.

In case the interface is integrated into any housing, rated to provide increased safety “Ex e“,

observe the following:

• Interface and housing must be protected from mechanical damage and environmental conditions out

of specifications.

• During installation the power supply must be disconnected.

• Protect cables from mechanical damage, corrosion and heat. Wherever such impact cannot be

avoided, extra protection as specified in DIN EN 60079-14 must be provided, or install conduits.

• Ingress protection rating IP54 must be maintained in any case. To achieve sufficient sealing, use a

washer, for instance a Viton- O-ring 20x2,5 mm between interface and housing. Fasten the interface

to flush with the housing.

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 ionised 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 ionisation 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.

2.3 Different models

The parameters of the Statox 501 PID interface are set ex works to the requirements of your application.

Target gas, sensor type and measuring range are hardware programmed.

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 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

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.

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. 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.

Position: gas access downwards (+ / - 15° ).

Place the sensor head close to potential gas leaks considering the specific gravity of the target gas, when

selecting the installation level.

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 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.

The Statox 501 PID needs a Statox 501 Control Module (software index 2.1 and higher) for

operation. Select the appropriate program prior to connecting the sensor head. (Progams 80 - 83).

Selecting the wrong program might destroy the sensor or cause malfunction!

If there are high potential differences in your plant, ground the shield only on the Control Module side.

After start up, allow 30 min warm up time. Then perform a calibration. The calibration can be neglected if

you have purchased an ex works calibration sensor head plus Control Module. In this case do not change

the program of the control module. Otherwise the calibration parameters will be lost! Ex - works -

calibrated components have labels with all relevant information on them.

After any change of program a calibration is mandatory.

If you want to form group alarms, you can use the optional common alarm module (Art. No. 557 387).

Connecting the interface:

Terminal Wire Contact

4 or 5 blue Power supply negative

3 black Signal

1 or 2 red Power supply positive

PEN

Netzteil

1 2 3 4 5

1 oder 2

4 oder 5

Controller Modul

interner Bus

918 817 716 12 11

+24V

Controller Modul

interner Bus

+24V

56 13 14 15 613 14 15

1 2 4 5

(optional)

Sammelalarm

Modul

918 817 716 12 11 17 18 9 7 8 16 14 15 613 5 4

501 PID 501 PID

5-wire mode 3-wire mode

Electrical connections for Statox 501 PID sensor heads. 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.

• To enter or exit the calibration mode hold the magnetic pin on to the contact area on the type plate.

Different modes of operation:

LED mode Control Module display activity

LED flashing green /

red alternatingly initial phase first ----, then 0 ---

green measuring mode actual concentration ---

flashing green calibration mode see Control Module

display

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

red Error: wrong program 0 select appropriate program

6 Calibration with gas

A calibration is due after installation, sensor replacement or in time intervals as required by local

regulations. 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 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:

Alarm threshold

c Isobutene =

Response factor

Example: Measuring range 0 - 1000 ppm Methylmethacrylate, 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

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 calibration menu 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 „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 „CAL“ is flashing, press

„Enter“ again.

• Now enter the product of span gas concentration multiplied by the response factor.

Example: Calibration to methyl methacrylate with 100 ppm Isobutene.

You have to enter 100 ppm * 1,6 = 160 (The reponse factor of methyl metacrylate is 1,6)

In case the sensor signal is too low, you will get the message „SenS“ on the Control Module. Proceed

as described in the next chapter.

• Remove the gas adapter and switch the gas off.

• Push the „Reset“ button on the Control Module to leave the calibration menu.

• Touch the contact area on the PID with the magnetic pin to enter the measuring mode. The LED

should be green then.

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 „SenS“ 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.

8.1 Lamp cleaning / replacement of consumables

8.1.1 Removing the sensor

Protect the sensor slot by re - installing the retaining nut

(see chapter 8.1.4) and closing it with the blind plug.

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.

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