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Compur 4120 manual

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Table of contents for the manual

  • Page 1

    Operation Manual Compur Statox 4120[...]

  • Page 2

    Compur Statox 4120 This document is subject to changes without notice. Regular updates can be viewed on our web site www.compur.com You are welcome to communicate any proposal how to improve this document to Compur Monitors. Copyright Compur Monitors GmbH & Co. KG Published by: Compur Monitors GmbH & Co. KG Weissenseestrasse 101 D-81539 Mü[...]

  • Page 3

    Compur Statox 4120 Contents Seite 1. Important notice 4 2. The Statox 4120 System: Pur pose of use and description 4 2.1 Statox 4120 sensor head 5 2.2 Statox 4120 rack 6 2.3 Statox 4120 control module 8 2.4 Diagnostic box 9 3. Installation and electrical connections 10 3.1 Statox 4120 sensor head 10 3.1.1 Mounting 10 3.1.2 Connecting the signal cab[...]

  • Page 4

    Compur Statox 4120 1. Important notice Statox 4120 is an explosion proof system for the detection of toxic gases. It can be operated in hazardous areas classified division 1 and 2. Before installing and putting Statox into operation read and observe this manual! To operate the system safely, observe this m anual carefully. It must be operated and m[...]

  • Page 5

    Compur Statox 4120 2.1 Statox 4120 sensor head pic. 1: Statox 4120 sensor head 1 Bottom part 2 Statox 4120 sensor 3 Statox 4120 dust filter 4 Gas generator 5 Statox 4120 pump 6 Statox 4120 filter cartridge 7 Buffer battery for pump operation 8 Water container 9 Electronics 10 Opto - coupler for communication with the diagnostic box 5[...]

  • Page 6

    Compur Statox 4120 pic. 2: Statox 4120 sensor head for Cl 2 und ClO 2 Operation principle Ambient air enters the sensor (2) by diffusion th rough an opening at the bottom. The sensor creates a current - signal proportional to the gas concentra tion. This signal is amplified, temperature compensated and linearised. As a digital signal it is transmit[...]

  • Page 7

    Compur Statox 4120 Construction: The system consists of a 19“-4-HE rack with backplane and up to nine Statox 4120 control modules. Each Statox 4120 sensor head is communicating wi th one control module. The Statox 4120 rack is available in following designs: STATOX 4120 Rack ½ x 19“ for 4 Control modules STATOX 4120 Rack 19“ for 9 Control mo[...]

  • Page 8

    Compur Statox 4120 2.3 Statox 4120 control module Each Statox 4120 Control module has its own power supply. The intrinsically safe sensor head supply circuit is supplied by a separate secondary winding. pic.4: Statox 4120 Rack 1 19“ Rack 9 LED A1 2 Statox 4120 control module 10 LED A2 3 Button A2 11 Potentiometer for A2 4 Button A1 12 Potentiomet[...]

  • Page 9

    Compur Statox 4120  LED A1 (9) - On if pre - alarm threshold is exceeded  Display A2 (10) - On if main alarm threshold is exceeded  Button A1 (4) - Press and hold button A1 to display A1 thres hold. Adjust with Pot. (12). A1 must be < A2.  Button A2 (3) - Press and hold button A2 to display A2 threshold. Adjust with Pot. (11).  Bu[...]

  • Page 10

    Compur Statox 4120 3. Installation and electrical connections 3.1. Statox 4120 sensor head 3.1.1. Mounting The sensor head should be installed as close as possibl e to potential leaks. If it is used as industrial hygiene device it should be located between a potent ial leak and personnel working in the area. Parameters such as:  Air flow (wind, [...]

  • Page 11

    Compur Statox 4120 pic.7: Drilling plan for the mounting brackets 3.1.2. Connecting the signal cable The signal cable connects sensor head and control module. Use only shielded cable. The maximum cable length depends on the cable specifications. Cable: Length l Capacity C L [pF/m] Inductivity L L [mH/m] Approved parameters: U O , I O , C O , L O A [...]

  • Page 12

    Compur Statox 4120 Example of cable specifications: Max. cable capacity: l x C L = C o - C i = 107 nF Max. cable inductivity: l x L L = L o - L i = 6,6 mH Diameter: > 0,75 mm 2 The Statox 4120 Systems will work reliably if the electrical resistance is : R L < 50 Ω . Most commonly the maximum length is limited by the cable capacity. Example:[...]

  • Page 13

    Compur Statox 4120 3.2 Statox 4120 rack Statox 4120 Rack must not be installed in hazardous areas. Observe local safety- and installation regulations. Protect any cable from tensile strain. The five - and the nine - contact terminals are plugged in. They can be removed to ease wire connection. pic.10: Backplane Statox 4120 Rack Installation instruc[...]

  • Page 14

    Compur Statox 4120 Installation instructions for the RFI-shielded Statox 4120 rack:  Use well shielded signal cable. The shield must make good contact with the RFI resistant cable glands. It must not be interrupted by connection box es. If the signal cable is run through such, these must also be equipped with RFI resistant cable glands. They mus[...]

  • Page 15

    Compur Statox 4120 Slide sw itch S1: S1 ON OFF 1 Relay active during alarm A2 Relay inactive at alarm A2 2 Relay active during alarm A1 Relay inactive at alarm A1 Toggle sw itch S3: S3 ON OFF 1 Detection mode - 2 Rest Alarm by resetbutton R auto - reset 3 Detection mode - 4 Detection mode - 5 Measured value accepted if logic signal is 0V - 6 Detect[...]

  • Page 16

    Compur Statox 4120 DIP switch S1 (see pic. 8) programs gas and meas uring range. If you change your Statox to another gas or measuring range, a hardware modification may be required and the electronics must be re - adjusted. This must be done by authorised personnel. Table 1: Sw itch position for H 2 S Measuring range: 0-30 ppm 0-50 ppm 0-100 ppm S[...]

  • Page 17

    Compur Statox 4120 Table 4: Sw itch position for Cl 2 Measuring range: 0-1,5 ppm 0-3 ppm 0-10 ppm S1/1 ON ON OFF S1/2 ON ON ON S1/3 ON ON ON S1/4 ON OFF ON S1/5 ON ON OFF S1/6 ON ON ON S1/7 OFF OFF OFF S1/8 ON ON ON E-PROM Index sensor head 12, 13, 14 12, 13, 14 12, 13, 14 E-PROM Index control module 02, 03 ≥ 02 02, 03 Table 5: Sw itch position f[...]

  • Page 18

    Compur Statox 4120 Table 8: Sw itch position for SO 2 Table 9: Sw itch position for NO 2 Measuring range: 0-0,5 ppm Measuring range: 0-15 ppm S1/1 OFF S1/1 ON S1/2 ON S1/2 ON S1/3 ON S1/3 ON S1/4 OFF S1/4 ON S1/5 ON S1/5 ON S1/6 ON S1/6 ON S1/7 ON S1/7 ON S1/8 ON S1/8 ON E-PROM Index sensor head 21 E-PROM Index sensor head 21 E-PROM Index control m[...]

  • Page 19

    Compur Statox 4120 4.5 Manually triggered self test of the sy stem Push and hold button T for 2 s to initiate a self test. The next self test will start automatically after 24 h. 4.6 System failure As soon as the Statox detects a faulty system condition the LED SF goes on and relay SF is activated. This will be the case if:  Self test not passed[...]

  • Page 20

    Compur Statox 4120 5.1 Using the diagnostic box Switch the diagnostic box on. Then connect it to t he opto- coupler receptacle on sensor head bottom. Keep the LED`s and the phototransistors of the opto- coupler clean for proper data transmission. 5.1.1 Operation and error codes of the diagnostic box Note: If a combination of push button operations [...]

  • Page 21

    Compur Statox 4120 5.1.2 Status messages of the sensor head Button ST scans the system status: Code Status and action required Passed  System OK. Error A1  Amplifier defective: Repeat adj ustment or replace pcb. Error B1  Check battery pack connection. Battery pack discharged or defective, replace. If battery pack discharges frequently, ch[...]

  • Page 22

    Compur Statox 4120 6. Maintenance and calibration 6.1 Inspection Statox 4120 Sensor head The following maintenance intervals are general re commendations. Specific applications may request different intervals.  Splash guard, visual inspection every 4 weeks  Dust filter, visual inspection every 4 weeks  Statox 4120 sensor, replace after exp[...]

  • Page 23

    Compur Statox 4120 Filter cartridge replacement  Remove tube  Remove filter cartridge and bearing  Clean air access opening  Replace filter cartridge and bearing  Replace tube Generator cell replacement  Disconnect generator cell, remove tube to pump  Remove generator cell  Replace generator cell  Replace tube  Connect[...]

  • Page 24

    Compur Statox 4120 Procedure:  Remove splash guard and replace it by test gas adapter.  Connect span gas cylinder. Do not open regulator yet!  Connect diagnostic box to sensor head.  Reading diagnostic box: Red LED fl ashing; - “ready” – “x.xxx ppm”  Push CAL button  Reading diagnostic box: “CALIBR”  Push ENT butt[...]

  • Page 25

    Compur Statox 4120 7. The maintenace request option Purpose: This option can differentiate between fatal errors in the sensor head and maintenance requirements. It requires a Statox 4120 control module equipped with EPROM Index ≥ 03. It also sets the analog output to 4 mA during the self test, if required. Operation modes: The Statox 4120 can ope[...]

  • Page 26

    Compur Statox 4120 Error C3 (Too low sensitivity during self test): S3/3 on the control module offers the option to c hoose if C3 shall be a maintenance request (position ON) or system failure (position OFF). The system failure messages A1 and C3 (both defined as SF): The sensor head still transmits measur ed values to the control module, but these[...]

  • Page 27

    Compur Statox 4120 pic.12: Electrical connections and short circuit contacts Short circuit contacts on the maintenance request pcb: Bridge Analog 0-1V Analog 4-20 mA Analog 4(0)-20mA* 1 ● 2 ● ● 3 ● 4 ● ● 5 ● 6 ● ● 7 ● * Analog output 0 mA, if PCS-relay active, f. i. duri ng self test, alarm threshold adjustment and if the diagno[...]

  • Page 28

    Compur Statox 4120 8. The option analog output inhibition This option inhibits the analog output if the logic signal of the control module (see pic. 3, terminal 11) is set to 5 V instead of 0 V. This is the case if the system is unable to provide a valid measured value, for instance if: - Alarm thresholds are adjusted or displayed - During self tes[...]

  • Page 29

    Compur Statox 4120 9. The option zero adjustment This option is available for COCl 2 sensor heads with measuring range 0.3 ppm only. The zero adjustment of the sensor is started via diagnostic box. System requirements: Sensor head EPROM index 18c, control module EPR OM index 03a, diagnostic box EPROM index 02.  A zero adjustment must only be don[...]

  • Page 30

    Compur Statox 4120 10. Technical data General: Gas Measuring range Cl 2 0-1.5 ppm, 0-3 ppm, 0-10 ppm CO 0-150 ppm COCl 2 0-0.1 ppm, 0-0.3 ppm, 0-0.5 ppm, 0-1.5 ppm, 0-15 ppm, 0-100 ppm HCN 0-15 ppm, 0-30 ppm, 0-50 ppm, 0-100 ppm HCl 0-100 ppm H 2 S 0-30 ppm, 0-50 ppm, 0-100 ppm ClO 2 0-0.5 ppm NO 2 0-15 ppm SO 2 0-5 ppm Accuracy at TLV: +/- 10 % Al[...]

  • Page 31

    Compur Statox 4120 Control module: Type: 5331 0x0 (115 / 230 VAC) Operating temperature: -20 to +40 o C Storage temperature: -30 to +60 o C Explosion protection : [EEx ib] IIC Operating environment: II 2 G power: 15 W per control module Supply voltage: 115 / 230 VAC Max. operating voltage U o : 22 V DC Max. operating current I o : 50 mA DC Max. ext[...]

  • Page 32

    Compur Statox 4120 11. Accessories and spare parts Art. Nr. STATOX 4120 ACCESSORIES 508885 STATOX Diagnostic box 518876 STATOX Diagnostic box charger 115 V 518850 STATOX Diagnostic box charger 230 V 509115 STATOX Control module service adapter 508588 STATOX Sensor head flow adapter 500223 STATOX Head Splash guard plug 500224 STATOX Head Calibration[...]

  • Page 33

    Compur Statox 4120 558435 STATOX Manual -E- 518330 STATOX Sensor head battery 506947 STATOX Sensor head bearing 236 mm 557874 STATOX Sensor head EPROM "12" 562197 STATOX Sensor head EPROM "13" 502052 STATOX Sensor head EPROM "14" 550700 STATOX Sensor head EPROM "15" 551695 STATOX Sensor head EPROM "17&qu[...]

  • Page 34

    Compur Statox 4120 Specifications are subject to c hange without notice, and ar e provided only for comparison of products. The conditions under which our products are used, are beyond our contro l. Therefore, the us er must fully test our products and/or information to determine suitabilit y for any intended use, app lication, condition or situati[...]