General Monitors / MSA Ultima X Series Gas Monitors Instruction Manual

Ultima® X Series Gas Monitors Instruction Manual In North America, to contact your nearest stocking location, dial toll-free 1-800-MSA-INST. To contact MSA International, dial (724) 776-8626. Inquiries can also be e-mailed to customer.service@msaSafety.com. © MSA 2014 - All Rights Reserved This manual is available on the internet at www.msaSafety.com Manufactured by MSA NORTH AMERICA 1000 Cranberry Woods Drive, Cranberry Township, PA 16066 (L) -Y Rev 9 10036101 "! WARNING THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL HAVE THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece of complex equipment, this instrument will perform as designed only if it is used and serviced in accordance with the manufacturer’s instructions. OTHERWISE, IT COULD FAIL TO PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR THEIR SAFETY COULD SUSTAIN SEVERE PERSONAL INJURY OR LOSS OF LIFE. The warranties made by Mine Safety Appliances Company with respect to the product are voided if the product is not used and serviced in accordance with the instructions in this manual. Please protect yourself and others by following them. We encourage our customers to write or call regarding this equipment prior to use or for any additional information relative to use or service. MSA Instrument Warranty 1. Warranty- Seller warrants that this product will be free from mechanical defect or faulty workmanship for the following periods: • Gas Monitor: eighteen (18) months from date of shipment or one (1) year from installation, whichever occurs first • Oxygen, Toxic or Catalytic Combustible Sensor: eighteen (18) months from date of shipment or one (1) year from installation, whichever occurs first • IR Sensor source: ten (10) years from date of shipment. All other IR components: two (2) years from date of shipment. This warranty is applicable provided the product is maintained and used in accordance with Seller's instructions and/or recommendations. This warranty does not apply to expendable or consumable parts whose normal life expectancy is less than one (1) year. The Seller shall be released from all obligations under this warranty in the event repairs or modifications are made by persons other than its own or authorized service personnel or if the warranty claim results from physical abuse or misuse of the product. No agent, employee or representative of the Seller has any authority to bind the Seller to any affirmation, representation or warranty concerning the goods sold under this contract. Seller makes no warranty concerning components or accessories not manufactured by the Seller, but will pass on to the Purchaser all warranties of manufacturers of such components. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, AND IS STRICTLY LIMITED TO THE TERMS HEREOF. SELLER SPECIFICALLY DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. " WARNING This is a class A product in accordance with CISPR 22. In a domestic environment, this product may cause radio interference, in which case the user may be required to take adequate measures. 2. Exclusive Remedy- It is expressly agreed that Purchaser's sole and exclusive remedy for breach of the above warranty, for any tortious conduct of Seller, or for any other cause of action, shall be the repair and/or replacement at Seller's option, of any equipment or parts thereof, which after examination by Seller is proven to be defective. Replacement equipment and/or parts will be provided at no cost to Purchaser, F.O.B. Seller's Plant. Failure of Seller to successfully repair any nonconforming product shall not cause the remedy established hereby to fail of its essential purpose. 3. Exclusion of Consequential Damage- Purchaser specifically understands and agrees that under no circumstances will seller be liable to purchaser for economic, special, incidental or consequential damages or losses of any kind whatsoever, including but not limited to, loss of anticipated profits and any other loss caused by reason of nonoperation of the goods. This exclusion is applicable to claims for breach of warranty, tortious conduct or any other cause of action against seller. i General Warnings and Cautions " WARNING 1. The Ultima X Series Gas Monitors described in this manual must be installed, operated and maintained in strict accordance with their labels, cautions, warnings, instructions, and within limitations stated. Verify that the class, group, and temperature ratings of the equipment agree with the actual classification of the location. 2. The Ultima X Series Gas Monitor is designed to detect gases or vapors in air. It cannot measure the concentration of gases or vapors in steam or inert or oxygen-deficient atmospheres. The oxygen sensor can measure oxygen-deficient atmospheres. 3. Electrochemical sensors are sealed units which contain a corrosive electrolyte. Should a sensor develop leakage, it must be immediately removed from service; then, remove it from the sensing head and discard it properly. Caution must be exercised so that the electrolyte does not contact skin, eyes, clothing or circuitry; otherwise, serious personal injury (burns) and/or equipment damage may result. 4. Use only genuine MSA replacement parts when performing any maintenance procedures provided in this manual. Failure to do so may seriously impair instrument performance. Repair or alteration of the Ultima X Series Gas Monitor, beyond the scope of these maintenance instructions or by anyone other than an authorized MSA service personnel, could cause the product to fail to perform as designed and persons who rely on this product for their safety could sustain serious personal injury or loss of life. 5. Do not locate the general-purpose enclosure models in an area which may contain a flammable mixture of gas and air; otherwise, an explosion may occur. The general-purpose Ultima X Series Gas Monitors can be a source of ignition and must not be mounted in an area where a flammable mixture of combustible gas and air may become present; otherwise, an explosion may occur. If such a location must be monitored, use an explosion-proof Ultima X Series Gas Monitor model. 6. The Ultima XIR Infrared combustible gas monitor detects the presence of most combustible gases by identifying the difference in the amount of infrared light energy absorbed during the presence of these gases. This monitor, however, does NOT detect the presence of hydrogen gas and must never be used to monitor for hydrogen gas. 7. The standard Ultima XIR Infrared Combustible Gas Monitor does ii not detect the presence of acetylene gas and the presence of acetylene gas will degrade sensor performance. Custom-built acetylene sensors are available through your MSA representative. 8. Gas detectors depend on an unimpeded gas flow for proper operation. In environments where contamination is possible, ensure that the flow remains unobstructed at the sensor. Failure to follow this may prevent gas detection and generate inaccurate readings. 9. CSA performance Certification to standard C22.2 No. 152 is valid only when the instrument is calibrated on methane per the instruction manual. 10. Install Product in accordance with all markings and the regulations of the country in use. 11. Product components may have different hazardous location ratings. Ensure all components are suitable for the area of installation and protection technique. Failure to follow the above can result in serious personal injury or loss of life. " CAUTION 1. As with all gas monitors of these types, high levels of, or long exposure to, certain compounds in the tested atmosphere could contaminate the sensors. In atmospheres where an Ultima X Series Gas Monitor may be exposed to such materials, calibration must be performed frequently to ensure that operation is dependable and display indications are accurate. 2. The Ultima X Series Gas Monitor must not be painted. If painting is done in an area where a Monitor is located, care must be exercised to ensure that paint is not deposited on the sintered, metal flashback arrestor in the inlet fitting of the Ultima X Series Gas Monitor, if so equipped. Such paint deposits would interfere with the diffusion process, whereby a sample of the atmosphere being monitored diffuses into the Monitor. 3. The only absolute method to ensure proper overall operation of an Ultima X Series Monitor is to check it with a known concentration of the gas for which it has been calibrated. Consequently, calibration checks must be included as part of the routine inspection of the system. 4. Protect the Ultima X Series Gas Monitor from extreme vibration. Do not mount the sensing head in direct sunlight as this may cause overheating of the sensor. Failure to follow the above can result in injury, product damage and/or an unsafe condition. iii Table of Contents Chapter 1, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Identifying Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Installing Your Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Installing the Ultima XA Gas Monitor . . . . . . . . . . . . . .1-6 Installing the Ultima XE Gas Monitor . . . . . . . . . . . . . .1-6 Installing the Ultima XIR Gas Monitor . . . . . . . . . . . . .1-8 Electrical Connections for Ultima X Gas Monitors . . . . . . . . .1-9 Wiring for all Models . . . . . . . . . . . . . . . . . . . . . . . . .1-10 Use of External Controllers . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Identify PCB Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Installing the Ultima X Remote Sensor Module . . . . . . . . . .1-20 Electrical Connections for Remote Sensors . . . . . . . . . . . . .1-21 Chapter 2, Start-up and Calibration . . . . . . . . . . . . . . . . . . .2-1 Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Calibration Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Ultima Calibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Ultima Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Calibration Output Signal . . . . . . . . . . . . . . . . . . . . . . .2-6 Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Ultima X Series Gas Monitor Calibration Procedure . . . . . . . .2-7 Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 Span Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 INITIAL Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Standard Calibration . . . . . . . . . . . . . . . . . . . . . . . . .2-13 OXYGEN Calibration . . . . . . . . . . . . . . . . . . . . . . . . .2-18 XIR Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 iv Chapter 3, Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Chapter 4, Maintenance . . . . . . . . . . . . . . . . . . . .4-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Ultima XIR Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . .4-4 Replacing an Ultima XE or Ultima XA Sensor . . . . . . . . . . . .4-5 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Appendix A, Optional Features . . . . . . . . . . . . . . . . . . . . . . . .A-1 1) Internal Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Unpacking, Mounting and Wiring . . . . . . . . . . . . . . . .A-1 Ultima X Series Gas Monitor Internal Relays . . . . . . .A-2 Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3 Fault Relay or Trouble . . . . . . . . . . . . . . . . . . . . . . . . .A-4 Relay Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5 2) Optional RESET Push-button . . . . . . . . . . . . . . . . . . . . . . .A-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7 RESET Button Selection . . . . . . . . . . . . . . . . . . . . . . .A-7 Optional Push-button Calibration . . . . . . . . . . . . . . . .A-8 3) Optional Horn Relay Software . . . . . . . . . . . . . . . . . . . . . .A-9 To Activate the Horn Relay . . . . . . . . . . . . . . . . . . . . .A-9 To Reset the Horn Relay . . . . . . . . . . . . . . . . . . . . . . .A-9 Appendix B, Calibration Guide for Additional XIR/XI Gases .B-1 Appendix C, General Certification Information . . . . . . . . . . .C-1 v Appendix D, HART Specific Information . . . . . . . . . . . . . . . . .D-1 HART Field Device Specification . . . . . . . . . . . . . . . . . . . . . .D-1 Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2 Status Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3 Extended Device Status . . . . . . . . . . . . . . . . . . . . . . .D-3 Universal Commands . . . . . . . . . . . . . . . . . . . . . . . . .D-5 Common-Practice Commands . . . . . . . . . . . . . . . . . .D-5 Burst Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6 Catch Device Variable . . . . . . . . . . . . . . . . . . . . . . . . .D-6 Command #129: Read Sensor Gas Type . . . . . . . . . .D-7 Command #130: Read Device Real Time Clock . . . .D-7 Command #131: Read Alarm Setpoints . . . . . . . . . . .D-8 Command #132: Read Alarm Control Actions . . . . . .D-9 Command #133: Read Min, Max, Avg Values . . . . . .D-9 Command #134: Read Last Cal Date . . . . . . . . . . . .D-10 Command #135: Read Gas Table . . . . . . . . . . . . . . .D-10 Command #136: Read Input Voltage Value . . . . . . .D-10 Command #137: Read Auto Zero Comp Value . . . .D-11 Command #139: Read Sensor Status message . . . .D-11 Command #140: Read Swap Delay Status . . . . . . .D-11 Command #141: Read Cal Signal Status . . . . . . . . .D-12 Command #142: Read Alert Option Status . . . . . . . .D-12 Command #143: Read Sensor Temperature . . . . . .D-13 Command #144: Read Relay Normal State . . . . . . .D-13 Command #173: Write RTC . . . . . . . . . . . . . . . . . . .D-14 Command #174: Write Alarm Setpoints . . . . . . . . . .D-15 Command #175: Write Alarm Setpoint Control Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16 Command #176: Write Average Interval . . . . . . . . . .D-17 Command #177: Write Upper Trim Point . . . . . . . . .D-18 Command #178: Write Gas Table . . . . . . . . . . . . . . .D-19 Command #179: Write Sensor Data Sheet Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-20 Command #180: Write Sensor Swap Delay Enable .D-21 Command #181: Write Cal Signal Enable . . . . . . . .D-22 Command #182: Write Calibration Mode . . . . . . . . .D-23 Command #183: Write Calibration Abort . . . . . . . . .D-24 Command #184: Write Calibration Step . . . . . . . . . .D-25 vi Command #185: Write Alarm Acknowledge . . . . . . .D-26 Command #186: Write Protect Mode . . . . . . . . . . . .D-27 Command #187: Write Alert Option . . . . . . . . . . . . .D-28 Command #188: Write Relay Normal State . . . . . . .D-29 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-32 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-32 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-32 Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-32 Busy and Delayed-Response . . . . . . . . . . . . . . . . . .D-33 Long Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-33 Non-Volatile Memory . . . . . . . . . . . . . . . . . . . . . . . . .D-33 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-34 Write Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-34 Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-34 Capability Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-34 Default Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-35 Calibration Using a HART® Communicator . . . . . . . . . . . . .D-35 Sensor Zero Selection Menu . . . . . . . . . . . . . . . . . .D-35 Standard Zero/Span Calibration Selection Menu . . .D-37 Initial Calibration Procedures . . . . . . . . . . . . . . . . . .D-40 User Calibration Selection Menu . . . . . . . . . . . . . . .D-40 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-54 Span Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-54 Zero Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-57 vii List of Figures Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1-1. General-Purpose Ultima XA Monitor . . . . . . . . . .1-1 1-2. -Proof Ultima XE Monitor . . . . . . . . . . . . . . . . . . .1-2 1-3. Explosion-Proof Ultima XIR Monitor . . . . . . . . . . .1-2 1-4. General-Purpose XA Remote Sensor Module . . .1-3 1-5. Explosion-Proof XE Remote Sensor Module . . . .1-3 1-6. Explosion-Proof XIR Remote Sensor Module . . .1-4 1-7. Ultima XE and XIR Mounting Bracket . . . . . . . . .1-7 1-8. Ultima XIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 1-9. Ultima XE Grounding Terminals . . . . . . . . . . . . . .1-9 1-10. General-Purpose Two-Wire Operation . . . . . . .1-14 1-11. Explosion-Proof Two-Wire Operation . . . . . . . .1-14 1-12. General-Purpose Three-Wire Operation . . . . . .1-15 1-13. Explosion-Proof Three-Wire Operation . . . . . . .1-15 1-14. Two-Wire Printed Circuit Board (no HART Protocol) . . . . . . . . . . . . . . . . . . . . . .1-16 Figure 1-15. Two-Wire Printed Circuit Board (with HART Protocol) . . . . . . . . . . . . . . . . . . . . .1-17 Figure 1-16. Three-Wire Printed Circuit Board (no HART Protocol) . . . . . . . . . . . . . . . . . . . . . .1-18 Figure 1-17. Three-Wire Printed Circuit Board (with HART Protocol) . . . . . . . . . . . . . . . . . . . . .1-19 Figure 1-18. Remote Module General-Purpose Ultima X Series Wiring . . . . . . . . . . . . . . . . . . . .1-20 Figure 1-19. Remote Module Explosion-Proof Ultima X Series Wiring . . . . . . . . . . . . . . . . . . . .1-20 Figure 2-1. LCD Gas Concentration Display . . . . . . . . . . . . . .2-1 Figure 2-2. Ultima Calibrator . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Figure 2-3. Ultima Controller . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Figure 2-4. Ultima X Optional Push-button Calibrator . . . . . . .2-5 Figure 2-5. Apply ZERO Gas Flag . . . . . . . . . . . . . . . . . . . .2-14 Figure 2-6. Apply SPAN Gas Flag . . . . . . . . . . . . . . . . . . . . .2-15 Figure 2-7. Calibration End Display . . . . . . . . . . . . . . . . . . .2-17 Figure 4-1. "Change Sensor" Scrolls Across the Display . . . .4-6 Figure 4-2. Sensor Assembly and Sensor Guard for General-Purpose Model . . . . . . . . . . . . . . . . .4-7 Figure A-1. Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 Figure A-2. Relay Printed Circuit Board . . . . . . . . . . . . . . . . .A-6 Figure D-1. Zero cal step screen . . . . . . . . . . . . . . . . . . . . .D-41 viii Figure D-2. Span cal step screen . . . . . . . . . . . . . . . . . . . . .D-41 Figure D-3. Select Sensor Calibration from the Sensor Trim Menu . . . . . . . . . . . . . . . .D-42 Figure D-4. First Warning screen . . . . . . . . . . . . . . . . . . . . .D-43 Figure D-5. Second Warning screen . . . . . . . . . . . . . . . . . .D-44 Figure D-6. Standard Calibration function select screen . . .D-45 Figure D-7. Calibration initiated screen . . . . . . . . . . . . . . . .D-46 Figure D-8. Selection Confirmation screen . . . . . . . . . . . . . .D-47 Figure D-9. Sensor Zero Countdown screen . . . . . . . . . . . .D-48 Figure D-10. Zero Adjustment screen . . . . . . . . . . . . . . . . . .D-49 Figure D-11. Span Countdown screen . . . . . . . . . . . . . . . . .D-50 Figure D-12. Adjusting Span screen . . . . . . . . . . . . . . . . . . .D-51 Figure D-13. Calibration Completion message . . . . . . . . . . .D-52 Figure D-14. Calibration Gas Reminder screen . . . . . . . . . .D-53 Figure D-15. Loop Control Reminder message . . . . . . . . . .D-54 Figure D-16. Calibration Status screen . . . . . . . . . . . . . . . . .D-55 Figure D-17. Sensor Trim Point screen . . . . . . . . . . . . . . . .D-56 Figure D-18. Additional Sensor Status screen . . . . . . . . . . .D-57 Figure D-19. Device Status screen . . . . . . . . . . . . . . . . . . . .D-58 ix List of Tables Table 1-1. Installation Outline Drawing List . . . . . . . . . . . . . .1-10 Table 1-2. Cable Length and Wire Size for Units without Internal Relays . . . . . . . . . . . . . . . . . . . . . . . . . .1-11 Table 1-3. Installation Outline Drawings for Ultima X Power Supplies . . . . . . . . . . . . . . .1-12 Table 1-4. Remote Module Wiring and Placement . . . . . . . .1-22 Table 1-5. Remote Sensor Wiring Cable . . . . . . . . . . . . . . . .1-22 Table 1-6. Low Temperature Wiring Cable . . . . . . . . . . . . . .1-22 Table 2-1. Instrument Operation . . . . . . . . . . . . . . . . . . . . . . .2-2 Table 2-2. Factory-set Span Values . . . . . . . . . . . . . . . . . . . .2-9 Table 2-3. Calibration Guide for Combustible Gas Sensor . .2-11 Table 3-1. Performance Specifications . . . . . . . . . . . . . . . . . .3-1 Table 3-2. Sensor Response to Interferants . . . . . . . . . . . . . .3-4 Table 4-1. Operational Display Messages . . . . . . . . . . . . . . . .4-1 Table 4-2. Configuration Display Messages . . . . . . . . . . . . . .4-2 Table 4-3. Troubleshooting Guidelines . . . . . . . . . . . . . . . . . .4-2 Table 4-4. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Table A-1. Power Cable Distances for the Ultima X Series Gas Monitor with Internal Relays . . . . . .A-2 Table A-2. Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . .A-2 Table A-3. Push-button Calibration . . . . . . . . . . . . . . . . . . . . .A-8 Table D-1. Device Identification . . . . . . . . . . . . . . . . . . . . . . .D-1 Table D-2. Current Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2 Table D-3. Device Variables Exposed by the Ultima Monitor .D-3 Table D-4. Dynamic Variable implemented by Ultima Monitor D-3 Table D-5. Additional Device Status (Command #48) . . . . . .D-4 Table D-6. Supported Commands . . . . . . . . . . . . . . . . . . . . .D-6 Table D-7. Device-Specific Commands . . . . . . . . . . . . . . . . .D-7 Table D-8. Gas Type Descriptions . . . . . . . . . . . . . . . . . . . .D-30 Table D-9. Alarm Control Actions . . . . . . . . . . . . . . . . . . . . .D-30 Table D-10. Gas Table Values . . . . . . . . . . . . . . . . . . . . . . .D-30 Table D-11. Calibration Modes . . . . . . . . . . . . . . . . . . . . . . .D-31 Table D-12. Sensor Status Codes . . . . . . . . . . . . . . . . . . . .D-31 Table D-13. Sampling Rates . . . . . . . . . . . . . . . . . . . . . . . . .D-32 Table D-14. Command Response Times . . . . . . . . . . . . . . .D-33 Table D-15. Capability Checklist . . . . . . . . . . . . . . . . . . . . . .D-34 Table D-16. Default Configuration . . . . . . . . . . . . . . . . . . . .D-35 x Chapter 1, Installation General Description The Ultima X Series Gas Monitor is designed to sample the environment where mounted and alert you to potentially dangerous levels of your target gas, depending on your particular model. The Ultima X Series device uses various detection methods, depending on the gas of interest. Detection methods can be electrochemical, infrared, pellement or other technologies. The Ultima XE Gas Monitor is an explosion-proof device suitable for installation in hazardous locations. The Ultima XA Gas Monitor is a general-purpose version in a plastic enclosure for use in nonexplosive atmospheres only. The Ultima X Gas Monitor can be ordered with the standard 4 to 20 mA analog output or with an optional HART (Highway Addressable Remote Transducer) protocol, which is superimposed on the 4 to 20 mA signal. The unit is factory-calibrated and shipped ready for installation. The main sensor input is provided via a five-terminal interface that provides a digital interface for 3 VDC or 5 VDC sensor modules. Many different sensor modules are available, providing sensing capability for a large variety of gases. The operating range varies with the type of cell (e.g., electrochemical, pellistor or infrared combustible, etc.). Identifying Your Unit The Ultima XA Gas Monitor is housed in a rugged, plastic generalpurpose enclosure (FIGURE 1-1). Figure 1-1. General-Purpose Ultima XA Monitor 1-1 The Ultima XE Gas Monitor is housed in a 316 stainless steel explosion-proof enclosure (FIGURE 1-2 shows the Ultima XE with the optional explosion-proof HART port). . Figure 1-2. Explosion-Proof Ultima XE Monitor The Ultima XIR Gas Monitor is housed in a 316 stainless steel explosion-proof enclosure (FIGURE 1-3). Figure 1-3. Explosion-Proof Ultima XIR Monitor If your application requires the sensor head to be located separately from the control unit, all models are available with Remote Sensor Modules (shown in FIGURES 1-4, 1-5 and 1-6). 1-2 Figure 1-4. General-Purpose XA Remote Sensor Module Figure 1-5. Explosion-Proof XE Remote Sensor Module 1-3 Figure 1-6. Explosion-Proof XIR Remote Sensor Module To determine your sensor type and options, check the shipping carton. Checked items are included in the carton. The carton label identifies: • Type of unit supplied (Gas Monitor, Gas Monitor Less Sensor, or Remote Sensor Module) • Type of gas (combustible gas, toxic gas or oxygen) • Range [% LEL, PPM (parts per million), or %] • Output (2- or 3-wire, 4 to 20 mA, or 4 to 20 mA with HART) • Any options such as internal relays and/or LEDs. • If your unit contains internal relays, see Appendix A. Also check the sensor ID label located on the inside of the sensor. This can be viewed by unscrewing the lower portion of the sensor. If performing this while the unit is powered, see the following Warning. The sensor ID label identifies the detectable gas and the gas range. " WARNING For Ultima XE sensors marked Class I, Groups A, B, C and D and not used in Class II areas, unscrew sensor cap at least three full turns (but no more than four full turns from its tightly-closed position), wait 10 seconds, and then remove cap completely. Failure to follow this warning can result in the ignition of a hazardous atmosphere. For the Ultima XE Sensor marked Class II Groups F and G, atmosphere must be free of dust and the power removed from the unit before the sensor cap can be removed from the housing. Failure to follow this warning can result in the ignition of a hazardous atmosphere. 1-4 Your Ultima XE Series Gas Monitor may also include a separate HART Module if you ordered the following optional accessories: 1). Internal Power Supply and explosion-proof HART Port 2). External RESET Push-button and explosion-proof HART Port. Installing Your Gas Monitor NOTE: Reference installation outline drawings listed in TABLE 1-1. Generally, the Ultima X Series Gas Monitors or remote sensing module should be mounted close to the area where a leak is likely to occur or where the gas is expected. Install the Ultima X Series Gas Monitors or the remote sensing module at a high level (ceiling) or low level (floor), depending on the density of the gas most likely to be found. Install the unit so that the front display of the unit is not blocked or hidden from view. " CAUTION Mount the Ultima XE or XA Gas Monitor or remote sensing module with the sensor inlet fitting (FIGURE 1-1, 1-2, 1-4 or 1-5) pointed downward; otherwise, the inlet may become clogged with particulate matter or liquids. Mount the Ultima XIR Gas Monitor or XIR Remote Sensing Module with the sensor inlet fitting extended horizontally from the main enclosure (FIGURE 1-3 and 1-6) to prevent the build-up of particulate or liquid matter on the monitor's optical surfaces. Do not paint the Ultima X Series Gas Monitors. If painting is done in an area where a sensor is located, exercise CAUTION to ensure paint is not deposited on the sensor inlet fitting. Such paint deposits would interfere with the diffusion process, whereby a sample of the monitored atmosphere diffuses into the sensor. In addition, solvents in the paint may cause an alarm condition to occur. Protect the Ultima X Series Gas Monitors from extreme vibration. Do not mount sensing head in direct sunlight as this may cause overheating of the sensor. 1-5 " WARNING Do not locate the general-purpose enclosure models in an area which may contain a flammable mixture of gas and air; otherwise, an explosion may occur. The general-purpose Ultima X Series Gas Monitors can be a source of ignition and must not be mounted in an area where a flammable mixture of combustible gas and air may become present; otherwise, an explosion may occur. If such a location must be monitored, use an explosion-proof gas monitor. Installing the Ultima XA Gas Monitor Remove lid and drill enclosure for power, signal and optional relay cable entry. Use one of the following methods to mount the general-purpose Ultima XA Gas Monitor/Less Sensor or the Ultima XA Gas Monitor. • Using customer-installed wiring holes, install the Ultima XA Gas Monitor to the end of rigid conduit. • Use mounting holes in the corners of the Ultima XA enclosure to mount directly to a wall. • Use mounting holes in the corners of the Ultima XA enclosure to mount to the optional Mounting Kit (P/N 10047561); see FIGURE 1-7. • The Ultima XA gas sensor is not shipped attached to the main enclosure. Ensure the sensor wiring harness is through the entry and the sensor is pointed downward. Installing the Ultima XE Gas Monitor • The optional Mounting Bracket Kit (P/N 10047561) can be attached to the rear holes of the Ultima XE Gas Monitor (FIGURE 1-7). • The Ultima XE Gas Monitor main enclosure can be rotated 360° and mounted to ensure easy access to any of the four entryways. The electronics assembly inside the metal enclosure can be repositioned in any of the four self-aligning interior holes to ensure the display is properly oriented. • The Ultima XE Gas Monitor sensor is not shipped attached to the main enclosure. Ensure the sensor wiring harness is through the entry and the sensor is pointing downward. Tighten with a strap wrench. 1-6 . Figure 1-7. Ultima XE and XIR Mounting Bracket 1-7 Installing the Ultima XIR Gas Monitor " WARNING The Ultima XIR Gas Monitor contains no user- or field-serviceable parts and must be returned to the factory for repair. Any attempt to open the monitor will damage the unit and void the warranty. " CAUTION Under no circumstances should a wrench or pry-bar be applied to the two legs that support the unit's reflectors during installation or removal of the sensor (FIGURE 1-8). Applying force to the legs can permanently damage the monitor. It is recommended that the monitor's environmental guard be installed on the unit at all times. If the monitor is to be operated without the guard, frequent checks should be made to ensure particulate or liquid matter has not collected on the windows. • The optional Mounting Bracket (P/N 10047561) can be attached to the rear holes of the Ultima XE Gas Monitor (FIGURE 1-7). • The Ultima XIR Gas Sensor is factory-installed on the stainless steel gas monitor. The Ultima XIR Monitor must be installed with the XIR sensor in a horizontal position (see FIGURE 1-3) to prevent the build-up of particulate or liquid matter on the monitor optical surface. • The Ultima XIR Gas Sensor is intended for use only on metal enclosures. . Figure 1-8. Ultima XIR 1-8 Electrical Connections for Ultima X Gas Monitors " WARNING Before wiring the Ultima X Series Gas Monitors, disconnect power source supplying the monitor; otherwise, electrical shock or ignition of hazardous atmospheres could occur. For Ultima XE and XIR installations, the internal grounding terminal (located on the interior bottom of the Ultima XE main enclosure) must be used for equipment grounding. The external grounding terminal is only to be used as a supplemental bonding connection where local authorities permit or require such a connection. See FIGURE 1-9 for location of grounding terminals. . Figure 1-9. Ultima XE Grounding Terminals NOTE: For Ultima X Series units with internal relays, see Appendix A. This assembly is marked to identify power, ground and signal connections. • • A two-wire connection is possible for certain: • Toxic Gas models • Oxygen models A three-wire connection is required for all: • Combustible Gas models • Toxic and Oxygen models with internal relays. 1-9 Wiring for all Models Install wiring in accordance with the electrical code of the country in use and UL 61010-A1 or CSA C22.2 No. 1010.1, as applicable. In these installations, twisted-pair, instrument quality cable is recommended. Shielded cable is recommended for cable runs where interferences from radio frequency interference (RFI), electromagnetic interference (EMI) or other noise sources exist (such as motors, welding equipment, heaters, etc.). NOTE: See Installation Outline Drawings for wiring details as specified in TABLE 1-1. Table 1-1. Installation Outline Drawing List MODEL TYPE DOCUMENT NO. Ultima XA Gas Monitor SK3015-1027 Ultima XE Gas Monitor SK3015-1025 Ultima XIR Gas Monitor SK3015-1026 Conduit may also be needed in areas where large amounts of electrical noise is expected. Use caution when selecting a cable size. TABLE 1-2 expresses the maximum cable length when only using the Ultima X Series Gas Monitors. Ultima X Series options may take additional power which requires a heavier cable or a short cable run. Cable distances for units with internal relays are specified in Appendix A, TABLE A-1. When selecting cable size, consider future needs (i.e., addition of sensors and/or options available with the Ultima X Series Gas Monitors). See Chapter 3, TABLE 3-1, "Performance Specifications" for proper input voltage. Ensure that water and dirt are not able to enter the unit via the wire or conduit. If the unit is installed in a location known to be wet or damp, it is good practice to loop or bend the entry into the unit that prevents water incursion. All cable shields should be terminated to earth ground at one end only. 1-10 Table 1-2. Cable Length and Wire Size for Units Without Internal Relays GAS TYPE Oxygen or Toxic SENSOR OUTPUT DC VOLTAGE SUPPLY WIRE SIZE (AWG) MAXIMUM CABLE LENGTH WITHOUT HART (FEET) (METERS) MAXIMUM LOAD RESISTANCE (OHMS) 2 Wire 12 VDC 22 4000 1219 900(w/HART) 274 (w/HART) 100 50 (w/HART) 24 VDC 22 7,000 500 2134 Oxygen or Toxic 3 Wire 24 VDC 22 10,000 3048 500 Combustible 3 Wire 12 VDC 18 900 274 250 16 1,400 427 250 12 3,600 1097 250 18 2,500 762 500 16 4,200 1280 500 Combustible XIR XIR 3 Wire 3 wire 3 wire 24 VDC 12 VDC 24 VDC 12 10,000 3048 500 18 300 91 250 16 500 152 250 12 900 274 250 18 2,000 610 500 16 3,500 1067 500 12 5,000 1524 500 An external power supply is required to supply 8-30 VDC to the Ultima X Series Gas Monitor (For power requirements, see Chapter 3, "Specifications"). All connections should be made by following appropriate wire code procedures. For proper installation of an AC power supply used with an Ultima X Series transmitter, refer to the following drawings for detailed information. Optional 12 VDC or 24 VDC internal and external power supplies can be ordered with the Ultima X Series Gas Monitors. 1-11 Table 1-3. Installation Outline Drawings for Ultima X Power Supplies MODEL XA XE POWER SUPPLY POWER SUPPLY OUTPUT VOLTAGE POWER SPECIFICATION INSTALLATION OUTLINE DRAWING NUMBER 10000020129 External 12 VDC 1.25 Amps, 15 W External 24 VDC 0.46 Amps, 11 W 10000020127 Internal 12 or 24 VDC see above SK3015-1027 External 12 VDC 1.25 Amps, 15 W 10000020130 External 24 VDC 0.46 Amps, 11 W 10000020128 Internal 12 or 24 VDC see above SK3015-1025 (XE) or SK3015-1026 (XIR) Use of External Controllers The Ultima X Series Gas Monitors may be connected to any device capable of accepting 4-20 mA analog signals, such as: • Suprema Controller • Model 9010/9020 Controller • GasGard family controllers • Quad Gas Controller • Programmable Controllers • DCS’s, etc. " WARNING When using any of the the Ultima X Series accessories (such as relays) with the 4 to 20 mA output Ultima X Series Gas Monitor, a three-wire connection must be used. Failure to use a three-wire connection could damage the electronics within the Ultima X Series Gas Monitor which can result in serious personal injury or loss of life. Be sure to install your Ultima X Series Gas Monitor according to National Electrical and local procedural codes. Failure to do so can result in an unsafe condition. 1-12 Identify PCB Configuration • Identify the main pc board as a two-wire or a three-wire unit: • For XA Gas Monitors: while looking at the main pc board, locate the identifying label on the underside of the lid: • • A-ULTX-PCB-A-1 is a two-wire unit, 4-20 mA output • A-ULTX-PCB-A-2 is a two-wire unit with HART protocol on the 4-20 mA output • A-ULTX-PCB-A-3 is a three-wire unit, 4-20 mA output • A-ULTX-PCB-A-4 is a three-wire unit with HART protocol on the 4-20 mA output For XE and XIR Gas Monitors: locate the identifying label on the side of the plastic shroud for the main pc board: • A-ULTX-PCB-E-1 is a two-wire unit, 4-20 mA output • A-ULTX-PCB-E-2 is a two-wire unit with HART protocol on the 4-20 mA output • A-ULTX-PCB-E-3 is a three-wire unit, 4-20 mA output • A-ULTX-PCB-E-4 is a three-wire unit with HART protocol on the 4-20 mA output. 1-13 • Two-wire 4 to 20 mA Ultima X Series Monitors operate in the current loop mode (FIGURE 1-10 for general-purpose) (FIGURE1-11 for explosion-proof). . Figure 1-10. General-Purpose Two-Wire Operation . Figure 1-11. Explosion-Proof Two-Wire Operation 1-14 • Three-wire Ultima X Series Monitors operate in the current source mode (see FIGURE 1-12 for general-purpose) (FIGURE 1-13 for explosion-proof). . Figure 1-12. General-Purpose Three-Wire Operation . Figure 1-13. Explosion-Proof Three-Wire Operation 1-15 Figure 1-14. Two-Wire Printed Circuit Board (no HART Protocol) Installation of Two-Wire, 4-20 mA Output (no HART Protocol) 1. Connect 8-30 VDC power lead to J8-1 (see FIGURE 1-14) 2. Connect J8-2 to the 4-20 mA output on the remote system. 3. Connect the sensor module to main pc board connector J-1. 4. Assemble lid on the enclosure. 1-16 Figure 1-15. Two-Wire Printed Circuit Board (with HART Protocol) Installation of Two-Wire, 4-20 mA Output with HART Protocol 1. Connect 12-30 VDC power lead to J8-1 (see FIGURE 1-15). NOTE: The HART signal is not available below 12 VDC on the two-wire pc board. 2. Connect J8-2 to the 4-20 mA input on the remote system. 3. Terminate the 4-20 mA line with 230-500 Ohms of resistance. 4. Connect sensor module to main pc board connector J-1. 5. Assemble lid on the enclosure. 1-17 Figure 1-16. Three-Wire Printed Circuit Board (no HART Protocol) Installation of Three-Wire, 4-20 mA Output (no HART Protocol) 1. Connect 8-30 VDC power lead to J8-1 (see FIGURE 1-16) 2. Connect J8-2 to the 4-20 mA output on the remote system. 3. For three-wire operation, connect the signal ground to J8-3. 4. Connect the sensor module to main pc board connector J-1. 5. Wire for optional relays, if applicable (see Appendix A). 6. Assemble lid on the enclosure. 1-18 Figure 1-17. Three-Wire Printed Circuit Board (with HART Protocol) Installation of Three-Wire, 4-20 mA Output with HART Protocol 1. Connect 8-30 VDC power lead to J8-1 (see FIGURE 1-17) 2. Connect J8-2 to the 4-20 mA input on the remote system. 3. Terminate the 4-20 mA line with 230-500 Ohms of resistance. 4. For three-wire operation, connect the signal ground to J8-3. 5. Connect the sensor module to main pc board connector J-1. 6. Wire for optional relays, if applicable (see Appendix A). 7. Assemble lid on the enclosure. 1-19 Installing the Ultima X Remote Sensor Module The Remote Sensor Module is used with the Ultima X Gas Monitor for installations requiring remote placement of the gas sensor. FIGURES 1-18 and 1-19 show the general-purpose and explosion-proof configurations. Figure 1-18. Remote Module General-Purpose Ultima X Series Wiring Figure 1-19. Remote Module Explosion-Proof Ultima X Series Wiring 1-20 The Remote Sensor Module should be mounted in a manner similar to the Ultima X (see Chapter 1, "Installing Your Gas Monitor") and at a maximum distance outlined in TABLE 1-6. Permanently connect 1/4" ID tubing to the post on the windguard. Route this tubing to the Ultima X Gas Monitor, ensuring that there are no kinks, leaks or other obstructions. Secure this tubing near the monitor; it is used to deliver check gas to the sensor module during calibration. Electrical Connections for Remote Sensors " WARNING Before wiring the Ultima X Series Remote Sensor Module, disconnect the power source feeding the Remote Sensor Module and the Ultima X Series Gas Monitor/Less Sensor; otherwise, electrical shock or ignition of hazardous atmospheres could occur. " WARNING When installing an Ultima X Series Remote Sensor Module with its mating Ultima X Series Gas Monitor/Less Sensor, follow National Electrical and local procedural Codes; failure to do so can result in an unsafe condition. Five conductors are required for the Ultima XE and Ultima XA Remote Sensor Modules. Four conductors are required for the Ultima XIR Remote Sensor Module. The Ultima X Series Monitor has a five-wire terminal to accommodate up to #16 AWG conductors. For wiring details, see the applicable Installation Outline Drawing listed in TABLE 1-1. Some installations require metal pipe or metallic conduit. In these cases, separate conductors or unshielded cable may be used. For open wiring, shielded wire or cable should be used to minimize the possibility of noise interference and contact with other voltages. Selection of this shielded cable must comply with local requirements. 1-21 Table 1-4. Remote Module Wiring and Placement GAS TYPE MINIMUM WIRE SIZE MAXIMUM DISTANCE Toxic and Oxygen 20 AWG 100 feet (30m) Catalytic Combustible 18 AWG 16 AWG 50 feet (15 m) 100 feet (30 m) *IR Combustible 16 AWG 12 AWG 50 feet (15 m) 100 fee (30 m) TABLES 1-7 and 1-8 show suggested cables for Ultima X Series installations; other cables are available which are also adequate. Table 1-5. Remote Sensor Wiring Cable SUPPLIER CATALOG NUMBER DESCRIPTION Alpha Wire Corp 5525 5535 5514 5 cond., shielded, 18 AWG 5 cond., shielded, 16 AWG 4 cond., shielded, 20 AWG Table 1-6. Low Temperature Wiring Cable SUPPLIER CATALOG NUMBER DESCRIPTION Alpha Wire Corp 45525 45366 45545 5 cond., shielded, 18 AWG 6 cond., shielded, 16 AWG 5 cond., shielded, 14 AWG At the Ultima X Series Remote Sensor Location: 1. Open the Ultima X Series Remote Sensor cover by removing lid. 2. For the Ultima XA Gas Monitor, route the power and signal cable from the Gas Monitor through a customer-created opening in the enclosure and wire it to the appropriately labeled connection on the terminal block (FIGURE 1-4). For the Ultima XE or XIR Gas Monitor, route the cable from the Gas Monitor through a wire entry hole in the enclosure and wire it to the appropriately labeled connection on the terminal block (FIGURE 1-5). 3. Verify the sensor connector is firmly seated on the terminal board. 4. Re-install the cover of the Ultima X Series Remote Sensor. 1-22 NOTES: Grounding • Incoming power and signal cable shield should be earth grounded at the power source. • Connect power and remote sensor cable shields to shield terminals on main pc board. • Provide shield terminations inside the sensor housing as indicated on Installation Outline Drawings for Remote Sensor. See TABLE 1-1 for Installation Outline Drawing document numbers. Cable Size • Cables larger than #16 AWG will require a splice of smaller cable to fit the connector. 1-23 Chapter 2, Start-up and Calibration Initial Start-up • The Ultima X Series Gas Monitors are factory-calibrated and ready for immediate use. • Once power is applied to the unit, the LCD shows a test of all display words. The software version number displays; then, a 30second (self-check) countdown for sensor stability begins. • During the 30-second countdown, the output signal is the same as the calibration signal when enabled during a normal calibration. This is described later in this chapter under "Ultima X Series Gas Monitor Calibration Output Signal". • For units with LEDs, the Alert red LED will be solid ON during the 30-second countdown. • After the 30-second countdown, observe that the gas type and gas concentration (ppm, % Gas, or % LEL) alternately flash (FIGURE 2-1). • For units with LEDs, the Normal green LED will be solid ON after the 30-second countdown. • A complete listing of instrument operation features can be found in TABLE 2-1. During normal operation, the Ultima X Monitor displays the gas concentration of the surrounding environment. The corresponding output signal can be transmitted to a controller or read directly from the optional HART port with an HCF-approved communicator (such as the Emerson 375 HART Communicator, or equivalent). . Figure 2-1. LCD Gas Concentration Display 2-1 NOTE: The catalytic combustible model of the Ultima X Series Gas Monitors is capable of detecting concentrations of certain combustible gases above 100% LEL. When exposed to these concentrations, the Ultima X Series Gas Monitors will display one of two modes: • +LOC % LEL - The Ultima X Series Gas Monitor has been exposed to a high concentration of gas (above the LEL) and it is possible that the over-range condition may still exist. • OVER % LEL - The Ultima X Series Gas Monitor has been exposed to a high concentration of gas (above the LEL) and the over-range condition definitely still exists. " CAUTION In either mode, correct the condition causing the excessive gas level and vent or purge the area before attempting the following. In the +LOC % LEL mode, the output signal will also be locked at full-scale. If this condition occurs, the Ultima X Series Gas Monitor must be unlocked by performing a "Zero Function" with the Ultima X Series Gas Monitor Calibrator or Controller. The Ultima X Series Gas Monitor will not revert to a normal condition until a successful zero operation has been performed. This is an exclusive safety feature of the Ultima X Series Gas Monitor which pre-empts the possibility of ambiguous readings when the sensor is exposed to concentration of gas above 100% LEL In the OVER % LEL mode, the combustible gas is over the100%LEL range. It returns to normal operation when gas concentration level falls below 100%LEL. Table 2-1. Instrument Operation NOTES: 1 ALERT option causes the 4-20 mA output to be set to 3.75 mA during O2 sensor calibration (if the Cal Signal Option is also enabled). If the ALERT option is disabled and the Cal Signal enabled, the output is set to 21 mA during the O2 sensor calibration. 2 Swap Delay timeout is 60 seconds if enabled; 0 seconds otherwise. 3 The Swap Delay feature enables a one-minute hold-off of the Sensor Missing Fault, allowing the user to "Swap" or change sensors without having the 4-20 mA set to a fault condition. 4 Alarming operation are followed if the alarms are enabled. 2-2 OPERATION LEDs GREEN RED 4 to 20 mA FAULT RELAY NORMAL ON OFF steady Gas value Energized ALARMING FAULT OFF OFF Flashing ON steady Gas value 3.0 mA Energized De-energized POWER UP (HART Version) OFF ON steady <3.75 mA De-energized POWER UP (Non-HART Version) OFF ON steady <3.1 mA De-energized COUNT DOWN (All Versions) OFF ON steady ALERT option1 disabled; 21.0 mA for O2; 3.75 mA for others Energized if ALERT option disabled ALERT option1 enabled: 3.75 mA for all ON steady 3.0 mA if Swap Delay timeout2 expired, Swap Delay3 disabled or FAULT De-energized if ALERT option enabled3 De-energized if Swap Delay timeout2 expired, Swap Delay3 disabled or FAULT SENSOR MISSING/ COUNTDOWN OFF Previous gas value Energized if Swap Delay3 if Swap Delay3 enabled enabled and Swap Delay and Swap Delay timeout2 timeout2 not expired not expired SENSOR CAL CAL 4-20 OFF OFF CAL FAULT OFF UNDERRANGE OFF OVERRANGE/ LOC ON steady4 ON steady 3.75 mA if cal signal enabled and ALERT option1 enabled; gas value if cal signal disabled Energized if ALERT option disabled 21.0 mA for O2 if cal signal enabled and ALERT option1 disabled ON steady 4 mA if 4 mA calibration selected De-energized if ALERT option enabled1 20 mA if 20 mA calibration selected ON steady Gas value De-energized if ALERT option enabled1 De-energized two seconds every minute De-energized ON steady 3.0 mA if gas value 0 or less; gas value otherwise OFF4 21.0 mA Energized if ALERT option disabled Energized 2-3 Calibration Basics While the Ultima X Series Gas Monitor is factory-calibrated, it is good practice to calibrate the unit once it is installed in its final environmental destination. As with any type of gas monitor, the only true check of its performance is to apply gas directly to the sensor. The frequency of the calibration gas tests depends on the operating time and chemical exposures of the sensors. New sensors should be calibrated more often until the calibration records prove sensor stability. The calibration frequency can then be reduced to the schedule set by the safety officer or plant manager. Catalytic Combustible sensors located in areas where non-combustible chemicals may leak, particularly ones known to reduce the sensitivity (see following list) should be calibrated after such exposures. • Silanes, Silicates, Silicones and Halides (compounds containing Fluorine, Chlorine, Iodine or Bromine) • TABLE 3-2 in Chapter 3 lists interferants for electrochemical sensors. Before calibrating, the Ultima X Series Gas Monitor must be powered for a minimum of one hour to allow the sensor to settle into its new environment. " CAUTION Before attempting a calibration, power the unit at least one full hour. To ensure a fully functional sensor, perform a calibration check and adjustments at initial start-up and at regular intervals. When it is determined that calibration adjustments are required, the Ultima X Series Gas Monitor provides a one-man, non-intrusive method of adjustment at the unit. To calibrate the unit, one of the following accessories is necessary: • Ultima Calibrator P/N 809997 (FIGURE 2-2) • Ultima Controller P/N 809086(FIGURE 2-3) • Optional Push-button Calibration (FIGURE 2-4). Instructions for use of the optional push-button are given in Appendix A. 2-4 • HART®-compatible communications interface with Device Description Language capability (DDL) or generic HART interface with Manufacturer Specific Command capability. This hand-held HART Communicator must be HART revision 7 compliant and can be obtained from a HART-authorized supplier. See Appendix D for command definitions. . Figure 2-2. Ultima Calibrator . Figure 2-3. Ultima Controller . Figure 2-4. Ultima X Optional Push-button Calibrator 2-5 Ultima Calibrator The Ultima Calibrator allows the following functions: • Zero • Calibration (zero and span) • Changing address for some models. Ultima Controller The Ultima Controller also provides the above functions, plus access to the following features: • Three levels of alarm and relays • Date of last successful calibration • Maximum gas readings over selected time periods • Average gas readings over selected time periods • Changing span gas value from factory-set value • Access to real-time clock for time and date • Changing of full scale value. NOTE: See Ultima Controller/Calibrator manual (P/N 813379) for full functionality. NOTE: When an Ultima X Series Gas Monitor has an active latched alarm (indicated by a flashing alarm display): • An infrared (IR) remote device (such as the Ultima Calibrator or Controller) may be used to reset this alarm. • The next IR command it receives from a calibration device will reset the latched alarm (if it is not beyond the alarm threshold). The intended IR command will be ignored and interpreted as an 'alarm reset.' When the latching alarm function is inactive, other valid IR commands may be used. Calibration Output Signal The Ultima X Series Gas Monitor is shipped with the calibration output signal DISABLED so the output signal will track the gas concentration value during the calibration process. In some applications, it may be desirable to disable or lock the output to a pre-determined output value to prevent activation of alarm devices. The calibration signal can be ENABLED using the Ultima Controller or a HART controller with DDLor manufacturer-specific command capability. When the calibration 2-6 signal is enabled, the output signal is 3.75 milliamps for the 4 to 20 milliamp output models. NOTE: For oxygen sensors, the calibration signal will be 21 mA. Oxygen can be set to a 3.75 mA calibration signal by turning ON the ALERT option as described in the Ultima Controller manual. Calibration Kit Calibration Kits are available for the Ultima X Gas Monitors. For the recommended calibration kit, see Ultima Controller/Calibrator manual (P/N 813379). Ultima X Series Gas Monitor Calibration Procedure Read all calibration instructions before attempting an actual calibration. Also, identify and become familiar with all of the calibration components. During the calibration, it is necessary to quickly apply the span gas to the unit. Prior connection of the calibration components will aid in the ease of unit calibration. The only true check of any gas monitor's performance is to apply gas directly to the sensor. The calibration procedure must be performed regularly. NOTES: • If this is the first calibration or, if the sensor element has been changed or replaced, see Chapter 2, "Initial Calibration." • If this is an oxygen sensor, see subsequent section, "Oxygen Calibration." • If this is an XIR sensor, see subsequent section, "XIR Calibration." • Apply power to the unit at least 1 hour before calibrating. • Due to the unstable nature of Chlorine Dioxide (ClO2), Chlorine gas is used as a calibration simulant. If using the MSA calibration system and gas cylinder (P/N 710331), the response ratio is 2:1. In other words, the 2 ppm sample of Chlorine should be set to read 1 ppm of ClO2. The default value for the calibration gas on the ClO2 Ultima X Series Gas Monitor is 1 ppm. • For Cl2 and ClO2 calibration, do not mix regulators. Use only one regulator for each of these gases. They will not work properly if one regulator is used for multiple gases. 2-7 • Due to the reactivity of HCL with flow system components, the flow control regulator must only be used for HCL gas. HCL gas must be run through the flow control regulator and tubing for five minutes before attempting a calibration. After a successful calibration, flush the flow control regulator and tubing with 100% Nitrogen for five minutes. Store the flow control regulator in the desiccated bag included in Calibration Kit 54 or equivalent dry container. Equipment Required Three calibration kits (numbered 40, 41, and 54) are available from MSA for diffusion Ultima X Series Gas Monitors. Kit 40, 41, and 54 are housed in a convenient carrying case and contain all items necessary (less gas) for a complete and accurate calibration. These Kits do not calibrate Ultima X Series units equipped with a flow cap. NOTE: The calibration procedure for the sample draw Ultima XE/XA Monitor is the same as the procedure for the diffusion version, except calibration gas is applied to the calibration entry port of the inlet flow block and the cal kit for pumped units provides a flow matching regulator. The check or calibration gases can also be carried in the case. See TABLE 2-2 for the appropriate zero and span gas cylinders for your Ultima X Series Gas Monitor. TABLE 2-2 shows the recommended calibration kit for Ultima X Series Gas Monitors. Typically, Cal Kit 41 uses 0.25 LPM regulator and a calibration cap to contain the calibration gas. Cal Kits 40 and 54 use a 1.5 LPM regulator and no calibration cap. If Cal Kit 41 is recommended and the application is such that the calibration cap cannot be used (such as for a remote sensor application), Cal Kit 40 may be used. However, any time Cal Kit 40 is used, ambient wind conditions must be minimized to avoid a calibration with increased sensitivity. NOTE: The Ultima XIR uses Cal Kit 40 and does require a calibration cap. This calibration cap (P/N 10041533) is shipped with the product. 2-8 " WARNING These calibration kits contain zero caps to use in place of zero calibration gas. These caps can only be used when the ambient air does not contain the gas the monitor is detecting. If there is any doubt, use zero gas when zeroing the Ultima X Monitor; otherwise, improper calibration could occur. Span Gas Values The Ultima X Series Gas Monitor is factory-shipped with a preset span gas value (TABLE 2-2). This span gas value can be changed via the Ultima Controller or a HART controller; otherwise, the span gas must correspond to preset concentrations. See Section 3 of the Controller/Calibrator Manual (P/N 813379) to change the span gas value. See Appendix D for the equivalent HART command The span gas value of Ultima X Gas Monitor catalytic combustible models are pre-set to one of the broad categories shown in TABLE 2-2. Specific span gas values for all combustible models are listed under each category given in TABLE 2-3. " WARNING Always calibrate for the least sensitive gas or vapor (higher number category) expected to be measured (TABLE 2-3); otherwise, instrument readings may be incorrect. Table 2-2. Factory-set Span Values GAS TYPE SPAN GAS PRESET VALUES 0-100 PPM 60 PPM 0-500 PPM 300 PPM 0-1000 PPM 400 PPM RP CYLINDER P/N 710882 10027938 10028048 CAL KIT WARM-UP TIME 40 15 minutes SULFUR DIOXIDE 0-25 PPM 0-100 PPM 10 PPM 10 PPM 10028070 808978 40 15 minutes HYDROGEN SULFIDE 0-10 PPM 0-50 PPM 0-100 PPM 0-500 PPM 5 PPM 40 PPM 40 PPM 250 PPM 710414 10028062 10028062 10089547 40 15 minutes NITRIC OXIDE 0-100 PPM 50 PPM 10028074 40 15 minutes NITROGEN DIOXIDE 0-10 PPM 5 PPM 710332 41 41 30 minutes CARBON MONOXIDE RANGE 2-9 GAS TYPE RANGE 0-5 PPM 0-10 PPM 0-20 PPM 0-50 PPM SPAN GAS PRESET VALUES 2 PPM 2 PPM 10 PPM 10 PPM RP CYLINDER P/N 710331 CAL KIT WARM-UP TIME CHLORINE 41 41 30 30 30 30 10028066 10028072 0-10 PPM 8 PPM 10028070 41 30 minutes 0-3 PPM 1 PPM 710331 41 30 minutes OXYGEN 0-10% 0-25% 5% 20.8% 493580 10028028(2) 40 15 minutes 15 minutes NATURAL GAS(3) PETROLEUM VAPORS(3) (GASOLINE) GENERAL SOLVENTS(3) 0-100% LEL 0-100% LEL 25% LEL(1) 40% LEL(1) 10028034 10028034 40 40 15 minutes 15 minutes 0-100% LEL 55% LEL(1) 10028034 40 15 minutes NONMETHANE IR 0-100% LEL 29% LEL(1) 10028034 40 --- METHANE IR 0-100% LEL 50% LEL(5) 10028032 40 --- PHOSPHINE 2.0 PPM 0.5 PPM 710533 41 24 hours ARSINE 2.0 PPM 1.0 PPM 710533 41 24 hours SILANE 25 PPM 5 PPM 10014897 41 4 hours DIBORANE 50 PPM 15 PPM 10014897 41 30 minutes FLUORINE 5.0 PPM 4.0 PPM 710331 41 30 minutes BROMINE 5.0 PPM 2.5 PPM 710331 41 30 minutes AMMONIA 100 PPM 0-1000 PPM 25 PPM 300 PPM 10028076 10044014 40 40 30 minutes 30 minutes HYDROGEN ETHYLENE(6) OXIDE CARBON DIOXIDE IR 0-1000 PPM 0-10 PPM 500 PPM 4.0 PPM 10022386 10028070 40 40 30 minutes 24 hours 0-5000 PPM 0-2% 0-5% 2000 PPM 1.5% 2.5% 479266 807386 479265 40 --- 0-50 PPM 40 PPM 10028078 41 30 minutes HYDROGEN CYANIDE HYDROGEN FLUORIDE(7) CHLORINE DIOXIDE(4) HYDROGEN CHLORIDE minutes minutes minutes minutes NOTES: 1 Calibrated with Propane (.6% gas by volume) 2 Not required for standard calibration procedure 3 For combustible gas, it is good practice to calibrate unit with gas to be detected 4 ClO2 is calibrated with Cl2 or use ClO2 Calibrator Kit (P/N 710420) 5 Methane IR is calibrated with 50% LEL Methane 6 ETO is calibrated with SO2. 7 Hydrogen Fluoride (HF) is calibrated with Sulfur Dioxide (SO2). 10 ppm SO2 equals 8 ppm HF. 2-10 Table 2-3. Calibration Guide for Combustible Gas Sensor CATEGORY 31: FOR CATALYTIC TYPE 1S NATURAL GAS To detect the following gases, recalibrate with 0.6% propane & set Acetaldehyde 23 Hydrogen Acetylene 24 MAPP Gas Butadiene, 1, 3 25 Methane Carbon Monoxide 20 Methanol Ethane 24 Methylene Chloride Ethylene 25 Monomethyl Amine Ethylene Dichloride 22 Trigonox B span gas value accordingly 16 20 20 20 24 22 22 CATEGORY 32: FOR CATALYTIC TYPE 1S PETROLEUM VAPORS To detect the following gases, recalibrate with 0.6% propane & set 1, 1, 1-Trichloroethane 32 Ethylene Oxide Acetic Acid 28 Freon 152A Acetone 37 Gasoline Acrolein 28 Hexane Acrylonitrile 26 Isoprene Allyl chloride 30 Methyl Acetate Benzene 37 Methyl Chloride Butane (n) 36 Methyl Propene (2) Butane (iso) 32 Methyl t-Butyl Ether Butanol (iso) 38 Pentane (n) Butene-1 34 Pentane (iso) Butene-2 37 Pentene Butyl Acetate (n) 28 Propane Butylene 33 Propanol (n) Butyraldehyde 30 Propanol (iso) Chlorobenzene 38 Propylene Cyclohexane 37 Propylene Oxide Dimethoxyethane 26 Tetrahydrofuran Dioxane, 1, 4 39 Toluene Epichlorhydrin 33 Trichloroethylene Ethanol 30 Triethylamine Ether, Diethyl 37 Vinyl Acetate Ether, Dimethyl 30 Vinyl Chloride span gas value accordingly 36 28 35 40 33 34 32 29 35 36 36 35 29 36 37 33 33 30 39 35 38 34 32 CATEGORY 33: FOR CATALYTIC TYPE 1S GENERAL SOLVENTS To detect the following gases, recalibrate with 0.6% propane & set Amyl alcohol 43 JP-4 Butanol (n) 48 Methyl Cellosolve Butyl Acrylate 46 Methyl Ethyl Ketone Cellosolve 42 Methyl Isobutyl Ketone Di isopropylamine 42 Methyl Methacrylate Diethylamine 41 Naphtha, VM&P Ethyl Acetate 43 Octane (iso) Ethyl Acrylate 52 Propyl Acetate Ethyl Benzene 41 Styrene Heptane 42 Xylene Hexene 42 span gas value accordingly 41 49 52 53 40 53 52 45 42 50 2-11 CATEGORY 38: ULTIMA XIR METHANE To detect the following gases, recalibrate with 2.5% methane & set span gas value accordingly Methane 50 CATEGORY 39: ULTIMA XIR NON-METHANE To detect non-methane gases, recalibrate with stated % propane & set span gas value as given in Appendix B For additional gases for the Ultima XIR, see Appendix B. INITIAL Calibration When the unit is powered up for the first time, or when a new sensor module is placed in the unit, an INITIAL Calibration is recommended. This procedure enables the unit to gather data about the sensor to make accurate decisions for the CHANGE SENSOR function and the CAL FAULT function to work properly. During normal use, INITIAL calibration should only be used when a standard calibration will not clear a fault condition due to use of incorrect calibration gas or another similar situation. The INITIAL calibration is accomplished by: • simultaneously pressing the ZERO and CALIBRATE buttons of the Ultima Calibrator or • pressing and holding SPAN button on the Ultima Controller or • using the optional push-button calibration as outlined in Appendix A, "Optional Push-button Calibration" • using the HART Communicator as described in Appendix D. After starting the INITIAL calibration: • The display should show "APPLY ZERO GAS" • The word "ICAL" on the display distinguishes an INITIAL Calibration from a regular calibration. If "ICAL" does not appear, abort the calibration; then, retry the above procedure. NOTE: The zero or calibration process can be aborted at any time simply by pressing any button during the 30-second countdown on the Calibrator while aiming at the unit or by pressing and releasing the push-button if push-button calibration is available. • The remainder of the procedure is now the same as that for a regular calibration, as described in the following procedure. 2-12 Standard Calibration A standard calibration includes a "zero" and "span" procedure as described in the following procedures. If the user chooses to only perform a "zero" procedure, they may do so by pressing the ZERO button on the Calibrator or Controller instead of the CALIBRATE button as described as follows, or by using the optional push-button calibration as outlined in Appendix A, "Optional Push-button Calibration". Both the "zero" and the "span" functions are available on the HART Controller and are described in Appendix D. Zeroing 1. If Using the zero cap: If the ambient air is suitable, with no traces of the gas of interest, place the appropriate Calibration Kit zero cap over the SensorGard inlet and wait two minutes; otherwise, use zero gas. 2. If Using zero gas cylinder: a. Locate the zero gas cylinder and the Calibration Kit Flow Controller. b. Screw the Flow Controller onto the top of the zero gas cylinder. c. Locate the Tube Assembly from the cal kit. d. Push the smaller end of the Tube Assembly over the Flow Controller gas outlet and ensure tubing completely covers the gas outlet. e. When using Cal Kit 40, connect the other end of the tubing over the SensorGard inlet. When using Cal Kit 41, locate the cal cap (with hole for tubing) and push the tubing through the hole in the bottom of the cap. Then, connect the end of the tubing over the sensor inlet and push the calibration cap over the entire sensor inlet. f. Turn on zero gas flow by turning knob on the flow controller. 3. Point the Calibrator or Controller at the Ultima X Series Monitor display; press the CALIBRATE button. NOTE: The zero or calibration process can be aborted at anytime during the 30-second countdown interval; simply press any button on the Calibrator or Controller while aiming it at the unit or by pressing and releasing the push-button if pushbutton calibration is available. NOTE: The 30-second countdown interval is omitted for oxygen units; it is electronically zeroed. 2-13 The display shows: • A countdown from 30 to 0 seconds • APPLY ZERO GAS (FIGURE 2-5). . Figure 2-5. Apply ZERO Gas Flag 4. After the 30 second countdown: • The display alternates between "CAL" and a value. This value is the actual reading of the gas concentration the sensor is detecting. • Once the gas value on the display is stable, the alternating display stops. If the calibration is successful, the display will show END. a. If using the zero cap: remove it. b. If using a zero gas cylinder: 1) Turn OFF the gas flow by turning the flow controller knob. 2) Remove the tubing from the SensorGard. • If the calibration output signal is enabled during calibration, it will be held at the lockout value for an additional two minutes or until after the span routine if performing a full calibration. c. If CAL FAULT appears on the display, this indicates: 2-14 • An unsuccessful attempt to zero or calibrate the Ultima X Series Monitor • The Ultima X Series Monitor is operating with the calibration parameters defined before the calibration was attempted. • See Troubleshooting Guidelines found in Chapter 4. To extinguish the CAL FAULT, a complete, successful calibration procedure must be performed. The Ultima X Series Gas Monitor allows automatic zero adjustment only within a pre-defined range. It cannot make corrections outside this range, such as when an empty or wrong cylinder of gas is applied or failure to begin gas flow within the allotted 30-second countdown occurs. • If only a ZERO was performed, the procedure is complete and the user should return the calibration equipment to the cal kit. If a CAL was performed, the gas monitor will continue to the "span" sequence as described in the following section. Spanning 5. During a regular calibration, the Ultima X Series Gas Monitor automatically begins the span countdown after a successful zeroing of the unit. The span countdown is 30 seconds (FIGURE 2-6). NOTE: The span process can be aborted at any time during the countdown by simply pressing any button on the Calibrator while aiming it at the unit or by pressing and releasing the push-button if push-button calibration is available. . Figure 2-6. Apply SPAN Gas Flag 2-15 6. Locate the span gas cylinder and the Calibration Kit Flow Controller. 7. Screw the Flow Controller onto the top of the span gas cylinder. 8. Locate the Tube Assembly from the cal kit. 9. Push the smaller end of the Tube Assembly over the gas outlet of the Flow Controller and ensure that the tubing completely covers the gas outlet. 10.When using Cal Kit 40, connect the other end of the tubing over the SensorGard inlet. When using Cal Kit 41, locate the cal cap (with hole for tubing) and push the tubing through the hole in the bottom of the cap. Then, connect the end of the tubing over the sensor inlet and push the calibration cap over the entire sensor inlet. 11. Turn ON the gas flow by turning the flow controller knob. • It is good practice to have all calibration components previously assembled. • Ensure that any calibration gases are applied during the 30second count down period. • If a CAL FAULT indication is on the Ultima X Series Gas Monitor display before the user is able to apply the gas, a steady state gas condition was reached, causing the unit to use a wrong reading as a span indication. • It is necessary to restart the calibration process to clear this condition. 12. After the 30 second countdown: • The display alternates between "CAL" and a value. This value is the actual reading of the gas concentration the sensor is detecting. • Once the gas value on the display is stable, the alternating display stops. If the calibration is successful, the display will show END for approximately two seconds. (FIGURE 2-7). • No user adjustments are necessary. • The display will show the span gas value while the span gas is flowing to the unit. 13.Turn OFF the gas flow by turning the knob on the flow controller. 2-16 Figure 2-7. Calibration End Display • If the calibration output signal is enabled during calibration, it will be held at the lockout value for two additional minutes after END is displayed. • When the span gas is removed from the sensor, the sensor reading should change to show an ambient condition. • If a CAL FAULT appears on the display, this indicates: • An unsuccessful attempt to calibrate the Ultima X Series Gas Monitor • The Ultima X Series Gas Monitor is operating with the calibration parameters defined before the calibration was attempted. To extinguish the CAL FAULT flag, a complete calibration procedure must be performed. The Ultima X Series Gas Monitor allows automatic zero and span adjustments within a pre-defined range. It cannot make corrections outside this range, such as when an empty or wrong cylinder of gas is applied or failure to begin gas flow within the allotted 30second countdown occurs. 14. After a successful calibration, remove the tubing from the Flow Controller and remove the Flow Controller from the cylinder; return all items to their appropriate location in the Calibration Kit. 2-17 OXYGEN Calibration NOTE: If this is the first calibration after the sensor element is replaced, perform an "Initial Calibration." Oxygen calibration is slightly different from other gases. When the ZERO function is performed, the 30-second countdown is omitted because the Ultima/Ultima X Series unit performs the zero electronically. No calibration cap or zero gas is necessary. To meet the specification stated, it is necessary to span the oxygen Ultima/Ultima X Series Gas Monitor with the Calibration Kit and an oxygen cylinder. The concentration of oxygen in air varies slightly due to changing relative humidity and pressure levels. These variations in oxygen levels are detected by the oxygen Ultima/Ultima X Series Gas Monitor. To meet the reproducibility specification, it is necessary to use a calibration gas cylinder. This ensures the same concentration of oxygen for every calibration. 25% Oxygen Ultima/Ultima X Series Gas Monitor For the SPAN function, ambient air is generally adequate for the 25% oxygen Ultima/Ultima X Series Gas Monitor as the expected default span value is 20.8%. Therefore, when the display prompts "APPLY SPAN GAS" it would be adequate to simply allow the countdown to occur without applying gas. NOTE: If the sensor is located in an area of normally low or enriched oxygen, then a 20.8% oxygen sample must be applied when the display prompts: "APPLY SPAN GAS". XIR Calibration Although a full calibration (zero and span) can be performed on the Ultima XIR Gas Monitor, a no-gas calibration is sufficient to properly calibrate the monitor. Typically, a zero adjustment is all that is required for a full calibration. Normally, any degradation of the sensor's performance is associated with slight drifts in its zero response which, in turn, will adversely affect its span performance. Restoring the sensor's zero is typically sufficient to restore its span performance. A zero adjustment is performed by one of the following methods: • pressing the ZERO button on the Calibrator or Controller • using the optional push-button calibration as outlined in Appendix A, "Optional Push-button Calibration" • using the HART Controller or DCS, as described in Appendix D. 2-18 Follow the "Zeroing" instructions given earlier in this chapter. After completing the zeroing function, perform a span check to ensure proper operation. If the span check is unsuccessful, perform a full calibration. NOTE: For calibration of an XIR sensor operating with a Flow Cap, temporarily replace the Flow Cap with the Environmental Guard (packaged with the instrument) and perform the calibration procedure. " WARNING The Calibration Cap must be removed from the XIR environmental guard after completing the Zeroing and/or Spanning procedure; otherwise, the sensor cannot perform properly. Calibration Documentation The Ultima X Series Monitor records the date of the last successful calibration. This date can then be displayed on the front-panel LCD (with the use of the Controller or via the HART Controller). 2-19 Chapter 3, Specifications Table 3-1. Performance Specifications GAS TYPES Combustibles, Oxygen & Toxics TEMPERATURE RANGE TOXICS & OXYGEN OPERATING RANGE 0 to 40°C (32 to +104°F) *EXTENDED RANGE -20 to +50°C (-4 to +122°F) OPERATING RANGE NH3 0 to +30°C (32 to +86°F) *EXTENDED RANGE NH3, Cl2, ClO2 -10 to +40°C (+14 to +104°F) Calibrate within operating range CATALYTIC SINGLE & COMBUSTIBLES DUAL MODULES -40 to +60°C (-40 to +140°F) IR SINGLE & COMBUSTIBLES DUAL MODULES -40 to +60°C (-40 to +140°F) STORAGE TEMPERATURE RANGE DRIFT NOISE -40 to +70°C (-40 to +158°F) or limits of the sensor ZERO DRIFT SPAN DRIFT Less than 5%/year, typically Less than 10%/year, typically Less than 1% FS *Extended Range = The sensor may not meet all of the accuracy parameters listed. 3-1 ACCURACY GAS LINEARITY REPEATABILITY +2% FS +1% FS or 2 ppm +2% FS +1% FS +10% FS or 2 ppm +1% FS or 2 ppm CHLORINE SULFUR DIOXIDE +10% FS or 2 ppm +5% FS or 1 ppm +10% FS or 2 ppm +1% FS or 2 ppm NITRIC OXIDE NITROGEN DIOXIDE HYDROGEN CYANIDE HYDROGEN CHLORIDE +10% FS or 2 ppm +1% FS or 2 ppm +10% FS or 2 ppm +4% FS or 1 ppm +10% FS or 2 ppm +4% FS or 2 ppm +10% FS or 2 ppm +10% FS or 2 ppm CATALYTIC COMBUSTIBLE GAS IR COMBUSTIBLE GAS: METHANE, PROPANE <50% >50% <50% >50% +1% +1% +2% +2% CHLORINE DIOXIDE +10% FS or 2 ppm +5% FS or 1 ppm ETHYLENE OXIDE +10% FS +5% FS AMMONIA +10% FS +5% FS HYDROGEN +5% FS +5% FS PHOSPHINE +10% FS +10% FS ARSINE +10% FS +10% FS SILANE +10% FS or 2 ppm +1% FS or 2 ppm DIBORANE +10% FS or 2 ppm +1% FS or 2 ppm FLUORINE +10% FS or 2 ppm +5% FS or 1 ppm HYDROGEN FLUORIDE +10% FS +10% FS BROMINE +10% FS or 2 ppm +5% FS or 1 ppm CARBON MONOXIDE OXYGEN HYDROGEN SULFIDE 3-2 LEL +3% FS LEL +5% FS LEL - +2% LEL - +5% FS FS FS FS STEP CHANGE RESPONSE TIME TO REACH 20% OF SCALEOXYGEN & TOXICS Less than 12 seconds (typically 6 seconds) Less than 20 seconds (ETO) TIME TO REACH 50% OF SCALEOXYGEN & TOXICS Less than 30 seconds (typically 12 seconds) Less than 45 seconds (ETO) TIME TO REACH 50% OF SCALECOMBUSTIBLES Less than 10 seconds TIME TO REACH 90% OF SCALECOMBUSTIBLES Less than 30 seconds HUMIDITY 15 to 95% RH, non-condensing, 24 hours or less 15 to 60% RH (SO2**) 35 to 95% RH, long term SENSOR LIFE WIRING REQUIREMENTS CATALYTIC COMBUSTIBLES 3 years, typically OXYGEN & TOXICS 2 years, typically AMMONIA *** FULL REPLACEMENT WARRANTY 1 year from installation; 10 years for IR Sensor source (see "MSA Instrument Warranty" in this manual for complete details) OXYGEN & TOXICS 2-wire or 3-wire COMBUSTIBLES 3-wire RELAYS 3-wire **SO2 sensor should not be used in dirty or humid environments. ***0-100 ppm NH3 sensor is consumable at a rate of 10% for every 200 ppm/hours of exposure. 0-1000 ppm NH3 sensor is consumable at a rate of 10% for every 1500 ppm/hours of exposure. 3-3 POWER CON- OXYGEN & TOXICS SUMPTION * (TOTAL UNIT WITH RELAYS) CATALYTIC COMBUSTIBLES IR COMBUSTIBLES SIGNAL OUTPUT XA PHYSICAL XE PHYSICAL 8 VDC 12 VDC 24 VDC 250 mA max 175 mA max 100 mA max 8 VDC 12 VDC 24 VDC 600 mA max 400 mA max 210 mA max COMBUSTIBLES 8 VDC 870 mA max 12 VDC 550 mA max 24 VDC 290 mA max 3-wire current source OXYGEN & TOXICS 2-wire current sink 3-wire current source SIZE 9.423" H x 5.125" W x 3" D (239.34 mm x 130 mm x 76 mm) WEIGHT 1.5 pounds (0.7 kilograms) SIZE 10.280" H x 6.312" W x 3.911" D inches (261.11 mm x 160.33 mm x 99.34 mm) WEIGHT 10.4 pounds (4.72 kilograms) * The HART output signal is not available below 12 VDC on the two-wire pc board. Table 3-2. Sensor Response to Interferants If your readings are higher or lower than expected, it could be due to the presence of an interferant gas. • The gas listed in column 1 is presented to the sensor. • Column 2 indicates the concentration of that gas presented to the sensor. • The remaining columns indicate the respective responses by the sensors to each particular gas. For Example: Scan column 1 until you locate "hydrogen". Column 2 shows that 500 ppm of hydrogen was presented to the sensor. Column 3 shows that a CO (filtered) sensor gave an equivalent response of 200 ppm. Column 4 shows that an H2S sensor gave an equivalent response of 0.5 ppm, etc. 3-4 ND = No Data INTERFERANT CONCEN- CO TRATION filtered (PPM) H 2S Cl2 SO2 filtered NO NO2 HCN HCL Acetone 1000 0 0 0 0 ND 0 ND ND Acetylene 12000 0 0 0 0 ND ND ND ND Ammonia 25 0 0 0 0 ND 0 0 0 Arsine 1 0 0 0 0 0 ND ND 1 Benzene 20 0 0 0 0 ND ND 0 ND Bromine 2 0 0 2.5 ND 0 0 0 ND Carbon Dioxide 5000 0 0 0 0 0 0 0 0 Carbon Disulfide 15 0 0 0 0 0 ND 0.1 0 Carbon Monoxide 100 100 0.3 0 0.2 ND 0 0 0 Chlorine 5 0 -3 5 0 0 0 -0.2 0 Diborane 20 0 0 0 0 ND ND ND 0 Ethylene 50 100 0.1 0 0 ND 0 -0.3 ND Ethyl Alcohol 100 115 0 0 0 ND ND 0 ND Ethylene Oxide 10 ND ND ND 0 ND ND ND ND Ether 400 3 0 0 0 ND 0 ND ND Fluorine 5 0 0 2.5 0 0 ND 0 0 Freon 12 1000 0 0 0 0 0 0 0 0 Germane 1 0 0 0 0 0 ND ND 1 Hexane 500 0 0 0 0 ND 0 0 ND Hydrogen 500 200 0.5 0 15 ND -10 0 0 Hydrogen Chloride 50 0 0 0 0 4 0 ND 50 Hydrogen Cyanide 10 0 0 0 0 0 0 10 0 Hydrogen Fluoride 10 0 0 0 0 ND ND ND 6.5 Hydrogen Sulfide 10 1 10 -0.1 0 1 -8 50 40 MEK 200 0 0 0 0 0 0 ND ND Mercaptan (Methyl) 5 0 4.5 -0.1 0 1 ND 6 ND Methane 5000 0 0 0 0 0 0 0 0 Nitric Oxide 100 0 2 0 2 100 ND -3 40 Nitrogen Dioxide 5 -1 -4 0.5 -5 1.5 5 ND 0 Phosphine 0.5 ND 0 0 ND 0 ND ND 2 Silane 5 0 0 0 0 0 ND ND 7 Sulfur Dioxide 10 0 0.3 0 10 0.5 ND -0.3 0 Tichloroethylene 1000 0 0 0 0 0 ND ND ND 3-5 ND = No Data INTERFERANT CONCEN- ClO2 TRATION (PPM) HF PH3 ASH4 SiH4 GeH3 B2H6 Br2 Acetone 1000 0 0 ND ND ND ND ND 0 Acetylene 12000 0 0.1 ND ND ND ND ND 0 Ammonia 25 0 0 ND ND ND ND ND 0 Arsine 1 0 ND 0.7 1 1 1 5 0 Benzene 20 0 ND ND ND ND ND ND 0 Bromine 2 1 ND ND ND ND ND ND 2 Carbon Dioxide 5000 0 0 ND ND ND ND ND 0 Carbon Disulfide 0 0 0 0 0 15 0 ND 0 Carbon Monoxide 100 0 0 0 1 0 0 0 0 Chlorine 5 2.5 5 ND ND ND ND ND 4 Diborane 20 0 ND 3.5 5 4 5 20 0 Ethylene 50 0 0 0.5 1 1 1 2 0 Ethyl Alcohol 100 0 0 ND ND ND ND ND 0 Ethylene Oxide 10 0 ND ND ND ND Ether 400 0 0 Fluorine 5 1 ND ND ND ND ND ND 2 Freon 12 1000 0 0 0 0 0 0 0 0 Germane 1 0 ND 0.7 1 1 1 5 0 Hexane 500 0 0 ND ND ND ND ND 0 Hydrogen 500 0 0 0 0 0 0 0 0 Hydrogen Chloride 50 0 30 ND ND ND ND ND 0 Hydrogen Cyanide 10 0 0 ND ND ND ND ND 0 Hydrogen Fluoride 10 0 10 ND ND ND ND ND 0 Hydrogen Sulfide 10 0 3 ND ND ND ND ND 0 MEK 200 0 ND ND ND ND ND ND 0 ND ND ND ND ND ND ND ND 0 Mercaptan (Methyl) 5 0 ND ND ND ND ND ND 0 Methane 5000 0 0 ND ND ND ND ND 0 Nitric Oxide 100 0 2 ND ND ND ND ND 0 Nitrogen Dioxide 5 0.2 2.5 ND ND ND 0.5 ND 0.4 Phosphine 0.5 0 0 0.5 1 0.7 1 3 0 Silane 5 0 ND 0.1 0.2 5 0.2 15 0 Sulfur Dioxide 10 0 8 ND 1 2 3 6 0 Tichloroethylene 1000 0 0 ND ND ND ND ND 0 3-6 ND = No Data INTERFERANT CONCENTRATION (PPM) F2 NH3 H2 EtO Acetone 1000 0 ND ND ND Acetylene 12000 0 ND ND ND Ammonia 25 0 25 ND 0 Arsine 1 0 ND ND ND Benzene 20 0 ND ND ND Bromine 2 12 ND ND ND Carbon Dioxide 5000 0 0 0 ND Carbon Disulfide ND ND ND 15 0 Carbon Monoxide 100 0 0 2 ND Chlorine 5 10 0 0 0 Diborane 20 0 ND ND ND Ethylene 50 0 0 40 ND Ethyl Alcohol 100 0 ND ND 10 Ethylene Oxide 10 ND ND ND 10 Ether 400 0 ND ND ND Fluorine 5 5 ND ND ND Freon 12 1000 0 0 0 0 Germane 1 0 ND ND ND Hexane 500 0 ND ND ND Hydrogen 500 0 ND 500 ND Hydrogen Chloride 50 0 0 0 ND Hydrogen Cyanide 10 0 0 3 0 Hydrogen Fluoride 10 0 ND ND ND Hydrogen Sulfide 10 -0.2 0.5 1 ND MEK 200 0 0 ND 3 Mercaptan (Methyl) 5 -0.2 ND ND ND Methane 5000 0 ND ND ND Nitric Oxide 100 0 0 3 ND 0 Nitrogen Dioxide 5 1 ND ND Phosphine 0.5 0 0 0 0 Silane 5 0 ND ND ND Sulfur Dioxide 10 0 0 0 ND Tichloroethylene 1000 0 ND ND ND 3-7 Chapter 4, Maintenance General The Ultima X Gas Monitor is constantly performing a self-check. When a problem is found, it displays the appropriate error message (TABLE 4-3, "Troubleshooting Guidelines"). When a critical error is detected within the unit, the 4-20 mA output signal goes to a fault condition of 3.0 mA The "Sensor Warning" indication is not an error and does not affect the output. TABLES 4-1 and 4-2 describe the messages that users may see. Table 4-1. Operational Display Messages MESSAGE INDICATES MM/DD/YY Format for date scrolling VER Software version level will display next TIME Time will display next DATE Date will display next MIN MIN value for this interval will display next MAX MAX value for this interval will display next AVG AVG value for this interval will display next Adr Instrument's address will display next End End of calibration cycle Err An Error code will display next HR Special case indicates hours (two characters or less) OVER Gas value is greater than the set range 4-1 Table 4-2. Configuration Display Messages MESSAGE INDICATES CAL SIG ON Instrument will output the calibration signal during calibration CAL SIG OFF Instrument will output gas value during calibration LTCH/ Latching relay operations UNLTCH/ Non-latching relay operations INCR/ Increasing Alarm relay operations DECR/ Decreasing Alarm relay operations ENER Energized relay operations DENER De-energized relay operations CAL Normal calibration or 4-20 calibration cycle iCAL Initial calibration cycle OFF Alarm is OFF ON Alarm is ON RNGE Instrument's operational full-scale will display next PCAL Instrument's previous calibration date will display next TBLE Instrument gas table selection (if applicable) ALERT OP ON Instrument output will follow ALERT mode ALERT OP OFF Instrument output will not follow ALERT mode SWAP DELAY ON 60-second delay after sensor missing before fault SWAP DELAY OFF Fault occurs at sensor missing condition Table 4-3. Troubleshooting Guidelines (In priority order) MESSAGE INDICATES MN FLASH FAULT Program memory on the main PCBA is invalid Replace main pc board MN RAM FAULT Defective RAM memory location was found on the main PCBA Replace main pc board MN EEPROM FAULT EEPROM on the main PCBA is invalid Replace main pc board SENSOR MISSING Instrument has lost communication with the sensor module Connect or replace sensor SNSR FLASH FAULT Sensor module program memory is invalid Replace sensor module SNSR RAM FAULT Sensor module has a defective RAM location Replace sensor module SNSR DATA FAULT Sensor module datasheet is invalid Send reset data sheet command from the controller; if error persists, replace sensor INVALID SENSOR Attached sensor module is not compatible with main instrument Replace with correct sensor type 4-2 ACTION MN SUPPLY FAULT Power supply on main PCBA is out of range Check sensor wiring or replace main pc board RELAY FAULT Error with the internal relays has occurred Cycle power to the unit or replace main pc board SNSR POWER FAULT Power at the sensor module is out of range Correct wiring error, replace main pc board, or replace sensor module IR SOURCE FAULT IR source failure Replace or consult factory FIXED CURRENT MODE 4-20 mA is at a set level and will not change when Controller gas is applied or under fault conditions Exit Fixed Current Mode using the HART - SUPPLY FAULT The negative supply sensor module is out of range Check wiring or replace sensor module REF SIG FAULT IR reference detector failure Replace or consult factory ANA SIG FAULT IR analytical detector failure Replace or consult factory LOW SIGNAL Low IR signal Clean optics or replace sensor module. If in cleaning mode, no action required PARAM FAULT An operational parameter is out of range or sensor failed internal check Restart; replace, if necessary CONFIG RESET Main EEPROM memory was reset Use Controller to reset all configurations (e.g., alarm levels, calibration signals ON or OFF, etc) CHANGE SENSOR Sensor is at its end of life Replace sensor ZERO CAL FAULT OR SPAN CAL FAULT Instrument did not calibrate successfully Repeat calibration; check for proper calibration gas; check for blockage in the flow system SENSOR WARNING Sensor approaching end of life Prepare to replace sensor module CHECK CAL Calibration should be verified Perform bump test or calibration +LOC Instrument is locked in over-range condition Recalibrate or reset sensor OVER % LEL Sensor is exposed to a gas concentration above the LEL The instrument will return to normal operation when the gas concentration drops below 100% LEL und Under-range condition - quick Recalibrate or replace sensor Und Under-range condition - slow Recalibrate or replace sensor The highest priority message is displayed first. Lower priority messages are output only after the highest priority message is cleared. A manual selected scanning of low-priority messages is not possible. 4-3 Ultima XIR Cleaning Procedure The presence of particulate matter, oil films, liquid water, or the residue from water drops on the two monitor windows can adversely affect its performance. The environmental guard is designed to prevent foreign solids or liquids from reaching the monitor's optical system. Additionally, heating elements are incorporated into the unit to prevent water condensation. Under severe conditions, however, some material may collect on these surfaces and it may be necessary to occasionally check and clean the windows. 1. Remove the environmental or flow cap. 2. Place an opaque object (piece of paper, end of wrench handle, etc.) between the light source window and the mirror to completely obscure the light path for two to three seconds. • The Ultima XIR/Ultima XI Monitor enters the Cleaning Mode for two minutes. NOTE: While in the Cleaning Mode, the sensor will not respond to the presence of gas. • The analog current output is 3.0 mA during this time. • The display indicates 'low signal'’. 3. While both windows are made of a highly durable material that is not easily scratched, avoid excessive pressure when cleaning them. Clean, cotton-tipped applicators are the most convenient tool to remove material collected on the windows. • Use a dry applicator or one moistened with distilled water to wipe the window and remove dust. • Use an additional clean, dry applicator to remove any residual water. • Use an applicator moistened with isopropyl alcohol to remove heavy deposits of solids, liquids or oil films. Clean the window again with a second applicator moistened with distilled water; then, dry the window with a final applicator. • Avoid using excessive amounts of water or alcohol in the cleaning procedure, and inspect the window to ensure that the entire surface is clean. • 4-4 The unit remains in the Cleaning Mode for a minimum of two minutes. If active cleaning is still in progress at the end of this period, the sensor detects the motion of this object in its light path and automatically extends the Cleaning Mode for 15 seconds. Further 15-second Cleaning Mode extensions continue until no motion is detected. NOTE: When the cleaning process is complete, be sure to remove all objects from the light path. 4. When exiting the Cleaning Mode, the unit returns to normal operation. If water or isopropyl alcohol was used, allow the unit to operate for 15 minutes to completely dry before replacing the environmental guard and continuing to monitor for combustible gas. 5. Replace the environmental or flow cap. 6. After cleaning the windows, it is advisable to check the sensor’s response to both zero and calibration gas. " CAUTION Do not place foreign objects in the sensor's analytical region (except per the "Ultima XIR Cleaning Procedure" as described above); otherwise, the infrared beam can be partially blocked, causing the sensor to generate false readings. All objects must be removed from the sensor's analytical region for it to function properly. Similarly, if water or isopropyl alcohol is used to clean the sensor's windows, any residue from the cleaning procedure must be completely dissipated before returning the unit to service. Checking the sensor's response to zero gas is the best way to purge residual cleaning materials from the sensor and to make sure that sensor's reading is stable before zeroing or calibrating the sensor (see Chapter 2, "Start-up and Calibration"). Replacing an Ultima XE or Ultima XA Sensor The only routine maintenance item is the sensing element itself, which has a limited lifetime. When the Ultima X Series Gas Monitor's read-out indicates that the sensor must be changed, there is very little sensor lifetime remaining. It is good practice to obtain a replacement sensing element before the sensing element within your unit becomes inoperative. Typically, the Ultima X Series Monitor LCD display shows a maintenance message when the sensor is due for replacement (FIGURE 4-1). 4-5 Figure 4-1. "Change Sensor" Scrolls Across the Display " WARNING Electrochemical sensors are sealed units which contain a corrosive electrolyte. If electrolyte is leaking from the sensor, exercise CAUTION to ensure the electrolyte does not contact skin, eyes or clothing, thus avoiding burns. If contact occurs, rinse the area immediately with a large quantity of water. In case of contact with eyes, immediately flush eyes with plenty of water for at least 15 minutes. Call a physician. " CAUTION Do not install a leaking sensor in the sensing head assembly. The leaking sensor must be disposed of in accordance with local, state and federal laws. To obtain a replacement sensor, contact MSA at the address given under "Obtaining Replacement Parts." 1. There is no need to open the main enclosure; simply unscrew the sensor assembly located on the bottom of the Ultima X Series Gas Monitor main assembly (FIGURE 4-2). " WARNING For Ultima XE sensors marked Class I, Groups A, B, C and D and not used in Class II areas, unscrew sensor cap at least three full turns (but no more than four full turns from its tightly-closed position), wait 10 seconds, and then remove cap completely. Failure to follow this warning can result in the ignition of a hazardous atmosphere. 4-6 For the Ultima XE Sensor marked Class II Groups F and G, atmosphere must be free of dust and the power removed from the unit before the sensor cap can be removed from the housing. Failure to follow this warning can result in the ignition of a hazardous atmosphere. Figure 4-2. Sensor Assembly and Sensor Guard for General-Purpose Model 2. Identify the sensor assembly needed via the A-ULTX-SENS code on the interior sensor label and obtain the appropriate sensor assembly; replace sensor assembly. NOTE: Alarm setpoints and relay functions (energized/deenergized, latching/unlatching, and upscale/downscale) will not change when changing a sensor module from its current gas type to the same gas type (e.g., carbon monoxide to carbon monoxide). Alarm setpoints and the upscale/downscale relay function will change to the new sensor's default settings when changing a sensor module from its current gas type to a different gas type (e.g., carbon monoxide to oxygen). 3. The Ultima X Series Gas Monitor is shipped with the Sensor Swap Delay enabled. This means that the 4-20 mA output signal and the FAULT relay will hold off a fault indication for 60 seconds after the sensor missing indication is displayed on the instrument. This setting allows the operator to exchange sensor modules without a FAULT indication. 4. Refer to Chapter 2, "Calibration" to calibrate with the new sensor. It is recommended that all other maintenance be performed at an MSA factory-authorized service center. 4-7 Obtaining Replacement Parts See TABLE 4-4 for replacement sensor kits. To obtain a replacement sensor, address the order or inquiry to: Mine Safety Appliances Company 1000 Cranberry Woods Drive Cranberry Township, PA 16066 or call, toll-free, 1-800-MSA-INST. Inquiries can also be e-mailed to customer.service@msanet.com. " WARNING Use only genuine MSA replacement parts when performing any maintenance procedures provided in this manual. Failure to do so may seriously impair sensor and gas monitoring performance. Repair or alteration of the Ultima X Series Gas Monitor, beyond the scope of these maintenance instructions or by anyone other than authorized MSA service personnel, could cause the product to fail to perform as designed and persons who rely on this product for their safety could sustain serious personal injury or loss of life. Table 4-4. Replacement Parts GAS SELECTION GENERALPURPOSE PLASTIC MODEL A SENSOR KIT PART NO. EXPLOSIONPROOF MODEL E GENERALPURPOSE STAINLESS MODEL G Carbon Monoxide, 100 ppm A-ULTX-SENS-11-0... A-ULTX-SENS-11-1... A-ULTX-SENS-11-6... Carbon Monoxide, 500 ppm A-ULTX-SENS-12-0... A-ULTX-SENS-12-1... A-ULTX-SENS-12-6... Oxygen, 10% - compensated A-ULTX-SENS-13-0... A-ULTX-SENS-13-1... A-ULTX-SENS-13-6... Oxygen, 25% - compensated A-ULTX-SENS-14-0... A-ULTX-SENS-14-1... A-ULTX-SENS-14-6... Hydrogen Sulfide, 10 ppm A-ULTX-SENS-15-0... A-ULTX-SENS-15-1... A-ULTX-SENS-15-6... Hydrogen Sulfide, 50 ppm A-ULTX-SENS-16-0... A-ULTX-SENS-16-1... A-ULTX-SENS-16-6... Hydrogen Sulfide, 100 ppm A-ULTX-SENS-17-0... A-ULTX-SENS-17-1... A-ULTX-SENS-17-6... Chlorine, 5 ppm A-ULTX-SENS-18-0 A-ULTX-SENS-18-6... Sulfur Dioxide, 25 ppm A-ULTX-SENS-70-0... A-ULTX-SENS-70-1... Nitric Oxide, 100 ppm A-ULTX-SENS-20-0... A-ULTX-SENS-20-1... A-ULTX-SENS-20-6... Nitrogen Dioxide, 10 ppm A-ULTX-SENS-72-0... A-ULTX-SENS-72-1... A-ULTX-SENS-72-6... Hydrogen Cyanide, 50 ppm A-ULTX-SENS-22-0... A-ULTX-SENS-22-1... A-ULTX-SENS-22-6... Sulfur Dioxide, 100 ppm A-ULTX-SENS-71-0... A-ULTX-SENS-71-1... A-ULTX-SENS-71-6... 4-8 not available A-ULTX-SENS-70-6... GAS SELECTION GENERALPURPOSE PLASTIC MODEL A SENSOR KIT PART NO. EXPLOSIONPROOF MODEL E GENERALPURPOSE STAINLESS MODEL G Hydrogen Chloride, 50 ppm A-ULTX-SENS-23-0... not available A-ULTX-SENS-23-6... Chlorine Dioxide, 3 ppm A-ULTX-SENS-24-0... not available A-ULTX-SENS-24-6... Combustible Gas, 100% LEL Natural Gas and H2, 5% CH4 A-ULTX-SENS-31-0... A-ULTX-SENS-31-1... A-ULTX-SENS-31-6... Combustible Gas, 100% LEL Petroleum Vapors, 2.1% Propane A-ULTX-SENS-32-0... A-ULTX-SENS-32-1... A-ULTX-SENS-32-6... Combustible Gas, 100% LEL Solvents, 2.1% Propane A-ULTX-SENS-33-0... A-ULTX-SENS-33-1... A-ULTX-SENS-33-6... Comb Gas IR - Methane, 5% CH4 not available A-ULTX-SENS-38-1... not available Comb Gas IR - Non Methane, 2.1% Propane not available A-ULTX-SENS-39-1... not available Phosphine, 2 ppm A-ULTX-SENS-41-0... A-ULTX-SENS-41-1... Arsine, 2 ppm A-ULTX-SENS-42-0... A-ULTX-SENS-42-1... A-ULTX-SENS-42-6... Silane, 25 ppm A-ULTX-SENS-43-0... A-ULTX-SENS-43-1... A-ULTX-SENS-43-6... Germane, 3 ppm A-ULTX-SENS-44-0... A-ULTX-SENS-44-1... A-ULTX-SENS-44-6... Diborane, 50 ppm A-ULTX-SENS-45-0... not available A-ULTX-SENS-45-6... Bromine, 5 ppm A-ULTX-SENS-46-0... not available A-ULTX-SENS-46-6... Fluorine, 5 ppm A-ULTX-SENS-47-0... not available A-ULTX-SENS-47-6... Ammonia, 100 ppm A-ULTX-SENS-48-0... not available A-ULTX-SENS-48-6... Hydrogen, 1000 ppm A-ULTX-SENS-49-0... A-ULTX-SENS-49-1... A-ULTX-SENS-49-6... ETO, 10 ppm A-ULTX-SENS-50-0... not available A-ULTX-SENS-50-6... Ammonia, 0-1000 PPM A-ULTX-SENS-54-0... not available A-ULTX-SENS-54-6... Oxygen-Solvent Tolerant, 0-25% not available not available Carbon Monoxide, 0-1000 PPM A-ULTX-SENS-57-0... A-ULTX-SENS-57-1... A-ULTX-SENS-57-6... Chlorine, 0-20 PPM A-ULTX-SENS-61-0... not available A-ULTX-SENS-61-6... Oxygen-Solv & CO2 Tolerant, 0-25% not available A-ULTX-SENS-62-1... not available Oxygen-Low, 0-25% not available A-ULTX-SENS-63-1... not available Oxygen-Low, Solv Tolerant, 0-25% not available A-ULTX-SENS-64-1... not available A-ULTX-SENS-55-1... A-ULTX-SENS-41-6... SENSOR REPLACEMENT PARTS PART PART NO. XE Sensor Guard 10028904 XIR Sensor Guard 10041265 XIR Flow Cap 10042600 4-9 Appendix A, Optional Features 1) Internal Relays General Information The internal relays are designed to enable Ultima X Series Gas Monitors to control other equipment. There are four relays within the Ultima X Series Gas Monitor's module: • three alarm relays • one fault relay. Once configured, the relays activate when the Ultima X Gas Monitor detects an alarm condition. Similarly, the fault relay de-energizes when a fault condition is detected. The alarm relays are enabled in the non-latching, de-energized mode at the factory. • To disable or configure the alarms, you need the Ultima Controller (P/N 809086) or a HART Communicator. • The fault relay is normally-energized so the relay de-activates into a fail-safe condition if a fault or power outage occurs. See "Fault Relay" later in this Appendix. " CAUTION To prevent false alarms in the following instances, alarms/relays are temporarily disabled: 1) During the first minute from power-up 2) During calibration 3) For two minutes after calibration. 4) For one minute after the sensor missing indication displays (if the Delay feature is enabled). Unpacking, Mounting and Wiring Unpack, mount and wire the Ultima X Series Gas Monitor according to Chapter 1, "Installation". All electrical connections to the Ultima X Series Gas Monitor can be made via the clearly marked board-mounted connections. A-1 NOTE: To avoid electrical noise problems, do not run AC lines from relays in the same conduit or cable tray as the DC Signal lines. See Ultima Controller and Calibrator Manual (P/N 813379) for complete relay configuration information. Power cable wiring lengths for the Ultima X Series Gas Monitor with internal relays differ from models without internal relays (TABLE A-1). Table A-1. Cable Length and Wire Size for Units With Internal Relays GAS TYPE SENSOR OUTPUT DC VOLTAGE SUPPLY WIRE SIZE (AWG) MAXIMUM CABLE LENGTH WITHOUT HART (FEET) (METERS) 16 2,500 Oxygen or Toxic 3 Wire 12 VDC 24 VDC 16 8,000 2,438 500 Combustible 3 Wire 12 VDC 16 900 274 250 24 VDC 16 3,000 914 500 XIR 3 wire 12 VDC 16 400 152 250 24 VDC 16 2,500 762 500 762 MAXIMUM LOAD RESISTANCE (OHMS) 250 • In all installations, twisted instrument-quality cable is recommended. • Shielded cable is recommended in situations where radio frequency interference (RFI), electro-magnetic interference (EMI) or other electrical noise sources exist or are anticipated. Ultima X Series Gas Monitor Internal Relays Relay Specifications Table A-2. Relay Specifications TEMPERATURE RANGE -40 to +60°C (-40 to +140°F) HUMIDITY 15 to 95% RH, non-condensing RELAYS 3 ALARMS SPDT FAULT (NORMALLY-ENERGIZED) (Single pole, double throw) SPDT (Single pole, double throw) RELAY RATINGS At 125 or 250 VOLTS AC, NON-INDUCTIVE 5.0 Amps or 5 Amps @ 1/10 Hp At 30 Volts DC, NON-INDUCTIVE 5.0 Amps or 5 Amps @ 1/10 Hp A-2 Alarm Relays There are three alarm relays and one fault relay in the Ultima X Series Gas Monitors. The three alarm relays: • Activate when the Monitor detects a gas concentration level that exceeds setpoints • Alarms 1, 2 and 3 generally default to 10%, 20% and 30% of the full-scale reading and are set when the gas reading is above these values. • The Oxygen Model is a special case where: • • • Alarm 1 is set to 19% oxygen and activates below this setpoint • Alarm 2 is set to 18% oxygen and activates below this setpoint • Alarm 3 is set to 22% oxygen and activates above this setpoint. These default setpoints can be changed or verified via the Ultima X Controller. • See Ultima/Ultima X Controller and Calibrator manual (P/N813379). • The Controller can also enable the latching alarm function. Are factory-set to a de-energized position. • All relay connections have a normally-open set of contacts and a normally-closed set of contacts. These contacts are labeled as NCD (normally-closed, de-energized) or NCE (normallyclosed, energized). • The units are shipped with alarm relays factory-set to the deenergized (non-alarm) position and the trouble relay set to the energized (non-fault) position. • Upon activation, the relay contacts change state and remain changed for as long as: • • The alarm condition exists within the Ultima X Series Gas Monitor or • The latching mode is selected (see "Note on Resetting Latched alarms with Controller or Calibrator" in Chapter 2). These defaults can be changed or verified via the Ultima X Controller. A-3 Fault Relay or Trouble • It is a normally-energized, single-pole, double-throw (SPDT) relay. • During normal operation, the relay contacts are normally closed (NC) and normally open (NO) as shown in FIGURE A-1. NOTE: FIGURE A-1 depicts the version of the printed circuit board assembly without HART components. FIGURE 1-17 is the equivalent HART version. Figure A-1. Relay Contacts • • When a fault is detected or power is cut or turned OFF, these contacts change as follows: • normally-closed contacts open • normally-open contacts close. Provides an electrical path for fail-safe relay operation. In the event of any failure, including power loss, the relay will change to a fault condition. The Fault Relay can remain STEADY ON or PULSED. These two different modes can communicate different information to any PLC or DCS connected to the fault relay: • Fault Relay STEADY ON indicates: • Ultima X Series sensor is not connected properly or • Ultima X Series Gas Monitor internal fault or • An inoperative relay. A-4 • Fault Relay PULSED (once per minute) indicates: • Improper calibration of the Ultima X Series Gas Monitor or • Ultima X Series Gas Monitor CHECK CAL or CAL FAULT displayed. Relay Connections All electrical connections to internal relays can be made directly on the pc board (see FIGURE A-1). If you are connecting the relays to motors, fluorescent lighting or other inductive loads, it is necessary to suppress any sparks or inductive feedback that may occur at the relay contact. These effects may render the unit inoperative. One way to reduce these effects is to install a *Quencharc® across the load being switched. This device is available from MSA as (P/N 630413). " WARNING Before wiring the Ultima X Series Gas Monitors, disconnect power source supplying the monitor; otherwise, electrical shock or ignition of hazardous gases could occur. • The Ultima X Series Gas Monitor must be disassembled for relay wiring. The following procedure must be performed: 1. Remove the Ultima X Series Gas Monitor cover. 2. Pull on the wiring plugs to disconnect the connectors on the exposed board. NOTE: Observe connector locations for later re-insertion. 3. Route customer-supplied cable into the enclosure and connect to the appropriate wiring plugs. 4. Identify each conductor of the cable to enable proper connection at the control equipment. 5. If installing a RESET push-button: a. Route a two-conductor cable to terminal block J10 (FIGURE A-2). A-5 Figure A-2. Relay Printed Circuit Board • Route this cable with DC power to avoid noise interference from relay wiring. b. Connect the two-conductor cable to the two positions of terminal block J10. c. Identify the cable to enable proper connection at the button. d. Route cable to the push-button location; wire the button. 6. Re-install the wiring plugs. • Ensure that wiring plugs are firmly seated into their mates. 7. Pull the cable away from the unit to relieve any excess slack. • It is important not to have excess wire or cable within the module to avoid unwanted AC noise. 8. Re-install the cover of the Ultima X Series Gas Monitor. A-6 2) Optional RESET Push-button • If you are going to specify a switch to use with the Ultima X series, it should have, as a minimum, an equivalent (or better) approvals classification. The MSA provided pushbutton (P/N 10046923) is explosion-proof for Class I, Groups B, C, and D only. When relied upon for an explosion-proof capacity, do not install on equipment mounted or intended to be mounted in any other hazardous location. This pushbutton has been approved for use in Group A with the Ultima X Series when the protection technique is Nonincendive and the hazardous location is Division 2. Check product labels for protection technique. " WARNING When the pushbutton is used in conjunction with the Ultima XE Gas Monitor, the highest classification rating for the system is reduced to Class I, Div. 1, Groups B, C, & D. See MSA P/N 10048833 for installation instructions. Misuse can result in ignition of hazardous gases. General A RESET button is an optional feature to allow latching relays to be reset at the sensor location. • This may silence any alarm horns or turn OFF any equipment connected to the relays. • Latching relays can be configured on the Ultima X Series Gas Monitor via the Ultima Controller. • In a latching configuration: when the RESET button is pushed and any alarm is latched and not in its active alarm state, the alarm will reset. NOTE: An IR command can mimic the RESET button per Controller and Calibrator manual (P/N 813379). • In a non-latching configuration: the RESET button has no affect on the alarms. RESET Button Selection The RESET push-button can be acquired locally and wired to the Ultima X Series Gas Monitor during unit installation. A-7 • The RESET push-button must be a normally-open type with a momentary contact when pushed. • The electrical ratings must be at least 1 amp at 250 volts AC. • Specific push-buttons may be sourced by manufacturers such as Appleton Electric and Crouse Hindes, Inc. Optional Push-button Calibration The following procedure is used to enter the calibration by using the push-button. 1. Press and hold the push-button until the ♥ heart is displayed. 2. Release the push-button. • At this time, any recoverable alarms will be acknowledged. 3. Press and hold the push-button within three seconds of the push-button release. 4. Release the push-button when the desired calibration is displayed. See TABLE A-3. Table A-3. Push-button Calibration CALIBRATION TYPE DISPLAYED DATA PUSH-BUTTON HOLD TIME Zero Calibration CAL ZERO 5 seconds Span Calibration CAL SPAN 10 seconds ICAL iCAL 20 seconds • Refer to Chapter 2, "Startup and Calibration" for more information on calibration. 5. The calibration can be aborted during the 30-second countdown by pressing the push-button until the ♥ is displayed. • A-8 When the push-button is released, the calibration will be aborted. 3) Optional Horn Relay Software The Ultima X Series Gas Monitor is available with optional Horn Relay Software to allow an audible horn to be used with Relay 1. The following describes the use and functionality of this optional feature. Relay 1 is considered the Horn Relay. It does not function directly with Alarm 1 as in the standard software. To configure, note that: • Alarm 1 function is still active on the display • Alarm 1 display has its own latching/non-latching configuration setting • Horn Relay is configured as normally energized/de-energized via the Alarm 1 configuration setting; this is the only Alarm 1 configuration setting that uniquely controls the Horn Relay. • Alarm/Relay 2 and Alarm/Relay 3 action remains unchanged. NOTE: All relays, including Horn Relay hardware, have NO (normally open) and NC (normally closed) terminals. To Activate the Horn Relay The Horn Relay is initially active when any alarm (1, 2, or 3) condition is active. Once Horn Relay is reset, it is set again if the gas level: • clears below or above the active setpoint and then moves back through the setpoint or • continues to move through the next alarm set point. To Reset the Horn Relay The Horn Relay is reset by momentary contact closure using the pushbutton or by IR communications, regardless of whether or not the alarm has cleared. • The Horn Relay automatically resets if all alarms are clear (such as when all alarms are unlatched and fall below or rise above their setpoints for negative acting alarms). • If any alarm remains latched after the gas value moves out of the alarm range, the Horn Relay remains active until reset by the user. Clearing latched alarms is done by using the optional pushbutton or the IR Controller. A-9 Appendix B, Calibration Guide for Additional XIR/XI Gases B-1 B-2 Appendix C, General Certification Information C-1 C-2 Appendix D, HART Specific Information HART Field Device Specification The Ultima X Series Gas Monitor is available with an optional HART (Highway Addressable Remote Transducer) output communications protocol. With this option, the Ultima X Series Gas Monitor complies with HART Protocol Revision 7 and uses the 16-bit manufacturer and device codes. This document specifies all the device specific features and documents HART Protocol implementation details (e.g., the Engineering Unit Codes supported). These specifications assume the reader is somewhat familiar with HART Protocol requirements and terminology. This specification is a technical reference for HART-capable HOST Application Developers, System Integrators and knowledgeable End Users. It also provides functional specifications (e.g., commands, enumerations and performance requirements) used during Field Device deployment, maintenance, testing, and operations. It is recommended that the 4-20 mA output be the primary gas monitoring signal. The HART signal can be the secondary method. NOTE: The two-wire units’ HART protocol does not comply fully with Immunity Standards EN61000-4-3 (2006) and EN61000-4-6 (2007). Table D-1. Device Identification MANUFACTURER NAME MSA Manufacture ID Code 0x6008 MODEL NAME(S) Device Type Code 0xE09F ULTIMA HART Protocol Revision 7.0 Device Revision 1 Number of Device Variables 1 Notes: Physical Layers Supported FSK, 4-20 mA Physical Device Category Current Output D-1 Host Interface Analog Output The three-wire 4-20 mA current loop is connected on terminals marked 8-30 VDC(1), 4-20 mA OUT(2), and GND (3-wire)(3). The two-wire 4-20 mA current loop is connected on the 8-30 VDC(1) and 4-20 mA OUT(2) terminals. Refer to the installation outline drawings shown in Chapter 1, TABLE 1-1 for details. This is the main output from this transmitter, representing the process gas measurement, linearized and scaled according to the configured instrument range. This output corresponds to the Primary Variable (PV). HART communications are supported on this loop. This device has a Capacitance Number (CN) of 1. An inoperative device can be indicated by down-scale or up-scale current, depending on the sensor type. Current values are shown in TABLE D-2. Table D-2. Current Values Linear over-range Device malfunction indication DIRECTION VALUES (% OF RANGE) VALUES (MA OR V) Down Up 0% +105.0% +1.0% 4.00 mA 20.64 to 20.96 mA Down: less than Up: greater than 3.5 mA 20.96 mA Maximum current 22.0 mA Multi-drop Current draw 3.5 mA Lift-off voltage, 3-wire PCBA 8 VDC Lift-off voltage, 2-wire PCBA 13 VDC @ 250 Ohms D-2 Table D-3. Device Variables Exposed by the Ultima Monitor VARIABLE DESCRIPTION VARIABLE DESCRIPTION Gas Type Sensor gas type description Last Cal Date Date sensor was last calibrated Alarm Setpoints Gas value at which an alarm status bit is set Auto Zero comp Amount of compensated below zero drift Alarm Action increasing or decreasing alarm type, latching or non latching Alert option status See next section Alarm Status Indication of alarm setpoint exceeded Swap Delay status See next section Input Voltage Device input voltage level Min/Max/Avg Minimum, maximum and avg. value of PV over time Sensor Temp Avg Interval Time interval for min, max, avg (1,8 or 24 hr) Sensor Status Status returned by sensor Gas Table Linerization table selection Relay EN/De-eng Relay EN/De-eng RTC Date Device real time clock date Cal Sig Cal Signal Status RTC Min Device real time clock minutes RTC Hrs Device real time clock hours Table D-4. Dynamic Variable implemented by Ultima Monitor PV MEANING UNITS Gas Value %, %LEL, PPM Status Information Device Status Bit 4 ("More Status Available") is set when any failure is detected. Command #48 gives further details. Extended Device Status The Ultima Monitor can predict when certain maintenance will be required. This bit is set if a sensor fault or maintenance warning is detected. "Device Variable Alert" is set if the PV is out of limit. D-3 Table D-5. Additional Device Status (Command #48) Command #48 returns 5 bytes of data, with the following status information: BYTE BIT MEANING CLASS DEVICE STATUS BITS SET 0 1 2 D-4 0 Configuration Reset Error 4,7 1 Main ram fault Error 4,7 2 Main flash fault Error 4,7 3 EEprom write error Error 4,7 4 Incompatible sensor Error 4,7 5 Sensor quick under range Error 4,7 6 Sensor UNDer range Error 4,7 7 Calibration fault Error 4,7 0 Sensor Missing Error 4,7 1 Sensor Overrange Warning 2 Overrange Lock Warning 3 Parameter Fault Error 4 Sensor Warm up Warning 5 Sensor Config Reset Warning 6 Sensor Power Fault Error 7 5V Power Fault Error 0 Zero Countdown Info 1 Apply Zero Gas Info 2 Span Countdown Info 3 Apply Span Gas Info 4 Cal Aborted Info 5 Zero Fault Info 6 Span Fault Info 7 Cal OK Info 4,7 BYTE 3 4 BIT MEANING CLASS 0 End of Life Warning Warning 1 Sensor Swap Delay Info 2 Change Sensor Fault Error 3 Sensor Power Fault Error 4 Internal Comm Fault Error 5 Cal Sig Enable Info 6 Alert Option Enable Info 7 Relay Fault Error 0 Alarm 1 Set Warning 1 Alarm 2 Set Warning 2 Alarm 3 Set Warning DEVICE STATUS BITS SET 4,7 4,7 3 4 5 6 7 "Not used" bits are always set to 0. Some bits used in this transmitter indicate device or sensor failure and, therefore, also set bit 7 and bit 4 of the Device Status byte. These bits are set or cleared by the self-test executed at power up, or following a reset. They are also set (but not cleared) by any failure detected during continuous background self-testing. D-5 Universal Commands All Universal commands have been implemented in the Ultima Gas Monitor. The Ultima Gas Monitor returns a 7 in the Universal rev to indicate the device is using the expanded 16-bit manufacturer and device codes. Common-Practice Commands The following Common Practice commands have been implemented in the Ultima X device: Table D-6. Supported Commands COMMAND # DESCRIPTION 35 38 40 42 45 46 48 59 71 72 Write Range Values Reset “Configuration Changed” flag Enter/Exit Fixed Current Mode (See the following Warning) Perform Master Reset Trim DAC Zero Trim DAC Gain Read Additional Device Status Write Number of Response Preambles Lock Device Squawk 80 Read Device Variable Trim Point " WARNING The gas monitor will NOT register gas concentration changes on the 4-20 mA signal line if the operator places the unit in Fixed Current Mode. Implement alternate protection measures when the unit is placed in this mode. Make sure the unit is returned to Standard Operational Mode prior to use for gas detection. Failure to follow this warning can result in serious personal injury or loss of life. Burst Mode This device supports burst mode. Catch Device Variable This Field Device does not support Catch Device Variable. D-6 Table D-7. Device-Specific Commands The following device-specific commands are implemented in the Ultima Monitor: COMMAND # DESCRIPTION 129 Read Sensor Gas Type 130 Read Device RTC 131 Read Alarm Setpoints 132 Read Alarm Control Actions 133 Read Min/Max/Average Values 134 Read Last Cal Date 135 Read Gas Table 136 Read Input Voltage 137 Read Auto Zero Comp 139 Read Sensor Status 140 Read Swap Delay Status 141 Read Cal Signal Status 142 Read Alert Option Status 143 Read Sensor Temperature 144 Read Relay Normal State 173 Write Device RTC 174 Write Alarm Setpoints 175 Write Alarm Control Actions 176 Write Average Interval 177 Write Upper Trim Point 178 Write Gas Table 179 Write Sensor Data sheet Reset 180 Write Sensor Swap Delay Enable 181 Write Cal Signal Enable 182 Write Calibration Mode 183 Write Calibration Abort 184 Write Calibration Step 185 Write Alarm Acknowledge 186 Write Protect Mode 187 Write Alert Option 188 Write Relay Normal State Command #129: Read Sensor Gas Type Reads the Gas Type of the sensor currently connected to the Ultima Gas Monitor. D-7 Request Data Bytes None. Response Data Bytes BYTE FORMAT DESCRIPTION 0-3 ASCII Sensor gas type description (see TABLE D-8) Command #130: Read Device Real Time Clock Reads the Real Time clock hours and minutes from the Ultima X Gas Monitor. Request Data Bytes None. Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned RTC Hours 1 Unsigned RTC Minutes Command #131: Read Alarm Setpoints Reads the Ultima X Alarm Setpoint values. Request Data Bytes None. Response Data Bytes BYTE FORMAT DESCRIPTION 0-3 Float Alarm 1 Setpoint Value 4-7 Float Alarm 2 Setpoint Value 8-11 Float Alarm 3 Setpoint Value D-8 Command #132: Read Alarm Control Actions Reads the Ultima X Alarm Control Actions. Request Data Bytes None. Response Data Bytes BYTE FORMAT DESCRIPTION 0 Bit Enum Alarm 1 Control Actions (see TABLE D-9) 1 Bit Enum Alarm 2 Control Actions (see TABLE D-9) 2 Bit Enum Alarm 3 Control Actions (see TABLE D-9) Command #133: Read Min, Max, Avg Values Returns the Ultima minimum, maximum and average values recorded over an average interval. The average interval can be a value of 1 , 8, or 24 hours. For a one-hour interval, the value is updated at the top of each hour. For an eight-hour interval, the values are updated at 800, 1600 and 2400 hours. Request Data Bytes None. Response Data Bytes BYTE FORMAT DESCRIPTION 0-3 Float Minimum Value 4-7 Float Maximum Value 8-11 Float Average Value 12 Unsigned Average interval (1, 8, or 24) D-9 Command #134: Read Last Cal Date Returns the Ultima last calibration date of the currently connected sensor. Request Data Bytes None. Response Data Bytes BYTE FORMAT DESCRIPTION 0-2 Unsigned Last sensor calibration date Command #135: Read Gas Table This command returns the Ultima sensor Gas Table currently in use. The Gas Tables are linearization reference tables used with certain sensors to provide accurate response for different gases from the same sensor. Request Data Bytes None. Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Gas Table Number (see TABLE D-10) Command #136: Read Input Voltage Value Returns the Ultima input supply voltage value. This number should be in the range of 8-30 volts DC. Request Data Bytes None. Response Data Bytes BYTE FORMAT DESCRIPTION 0-3 Float Input Voltage Value D-10 Command #137: Read Auto Zero Comp Value Returns the Ultima Automatic Zero Compensation value. This value is accumulated by the device when the sensor reading attempts to drift below zero. This value is used to compensate the actual Zero calibration. The device will attempt to compensate up to 10 counts (display units) before setting the under-range bit. Command #139: Read Sensor Status message Returns the Ultima X sensor status message. This is a single byte containing hex codes. This byte is sent from the sensor module to the main processor and passed to the HART communications processor. Request Data Bytes BYTE FORMAT DESCRIPTION None Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Sensor Status message (See TABLE D-12) Command #140: Read Swap Delay Status This command returns the Ultima X sensor swap delay status. This is a single byte containing a 0 if disabled or 1 if enabled. If enabled, the swap delay will hold off a sensor missing error for 1 minute. This holdoff allows a sensor module to be swapped out with a calibrated sensor module without triggering a "sensor missing" alarm and dropping the 420 mA to the trouble level. Request Data Bytes BYTE FORMAT DESCRIPTION None Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Sensor Swap Delay Status (0 –disabled, 1 - enabled) D-11 Command #141: Read Cal Signal Status This command returns the Ultima X Cal Signal status. This is a single byte containing a 0 if disabled or 1 if enabled. If enabled, the output will be set to 3.75 mA during calibration (21 mA for oxygen). If disabled, the output will track the gas concentration. Request Data Bytes BYTE FORMAT DESCRIPTION None Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Sensor Cal Signal Status (0 –disabled, 1 - enabled) Command #142: Read Alert Option Status This command returns the Ultima X Alert Option Status status. This is a single byte containing a 0 if disabled or 1 if enabled. If enabled, the Alert Option will cause the 4-20 mA to be set to 3.75 mA during calibration of an Oxygen sensor (if the Cal Signal Option is also enabled). If the Alert Option is disabled and the Cal Signal enabled, the output will be set to 21 mA during Oxygen sensor calibration. Request Data Bytes BYTE FORMAT DESCRIPTION None Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Alert Option Status (0 - disabled, 1 - enabled) D-12 Command #143: Read Sensor Temperature This command returns the Ultima X Sensor Temperature. This is a single byte containing an integer value representing the temperature returned by the gas sensor. Not all gas sensors have an on-board temperature. Request Data Bytes BYTE FORMAT DESCRIPTION None Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Sensor temperature (°C) Command #144: Read Relay Normal State This command returns the Ultima X to the Normal relay state. This is a single byte containing a bit map of the three alarm relays’ non alarm states. Not all gas sensors have on-board relays. Request Data Bytes BYTE FORMAT DESCRIPTION None Response Data Bytes BYTE FORMAT DESCRIPTION 0 Bit 0 Alarm #1 0 = normally de-energized, 1 = normally energized 0 Bit 1 Alarm #2 0 = normally de-energized, 1 = normally energized 0 Bit 2 Alarm #3 0 = normally de-energized, 1 = normally energized D-13 Command #173: Write RTC Writes the Ultima Real Time Clock hours and minutes values.The real time clock is used to compute the minimum, maximum and average values and to date stamp the last sensor calibration date. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned RTC hours (0-23) 1 Unsigned RTC minutes (0-59) Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned RTC hours (0-23) 1 Unsigned RTC minutes (0-59) Command-Specific Response Codes CODE CLASS 0 Success 1-2 DESCRIPTION No Command-Specific Errors Undefined 3 Error 4 Parameter too large Undefined 5 Error 6 Too few data bytes Undefined 7 Error 8-15 16 Error 17-31 32 D-14 Access Restricted Undefined Error 33-127 In write protect mode Undefined Busy Undefined Command #174: Write Alarm Setpoints Writes the Ultima Alarm Setpoint values. The Ultima Gas Monitor uses alarm setpoint values to set alarm status bits in the device. The alarms can be enabled or disabled, set to increasing or decreasing and can be set to latching (see "Command 175: Write Alarm Setpoint Control Actions"). The adjustment range is greater than zero and less than full scale. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Alarm Number (1, 2, or 3) 1-4 Float Alarm Setpoint Value Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Alarm Number (1, 2 or 3) 1-4 Float Alarm Setpoint Value Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-2 Undefined 3 Error Parameter too large 4 Error Parameter too small 5 Error Too few data bytes 6 7 Undefined Error 8-15 16 Undefined Error 17-18 19 33-127 Access Restricted Undefined Error 20-31 32 In write protect mode Invalid device variable index Undefined Error Busy Undefined D-15 Command #175: Write Alarm Setpoint Control Actions Writes the Ultima X Alarm Setpoint Control Actions. The Ultima X Gas Monitor uses alarm setpoint Control Actions to enabled or disabled, set to increasing or decreasing and to set the alarm to latching or non latching. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Alarm Number (1, 2, or 3) 1 Bit Enum Alarm Control Action Value (see TABLE D-9) Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Alarm Number (1, 2, or 3) 1 Bit Enum Alarm Control Action Value (see TABLE D-9) Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-4 Undefined 5 Error 6 Too few data bytes Undefined 7 Error 8-15 16 Undefined Error 17-18 19 20-31 D-16 Invalid device variable index Undefined Error 33-127 Access Restricted Undefined Error 32 In write protect mode Busy Undefined Command #176: Write Average Interval Writes the Ultima Average Interval. This interval is in hours and is used by the device to determine the collection interval for Minimum, Maximum and Average values. The Average collection interval can be for 1, 8 or 24 hours. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Average Interval Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Average Interval Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors Error Invalid Selection 1 2 Undefined 3-4 5 Undefined Error 6 7 Undefined Error 8-15 16 33-127 In write protect mode Undefined Error 17-31 32 Too few data bytes Access Restricted Undefined Error Busy Undefined D-17 Command #177: Write Upper Trim Point Writes the Ultima X Upper Trim or Span point value. The Ultima Gas Monitor uses the Upper trim point value to perform Span calibration. When a Span calibration is performed, the device automatically sets the highest reading obtained to this Span value. The adjustment range on the Upper Trim Point is one display unit to the full-scale limit. Request Data Bytes BYTE FORMAT DESCRIPTION 0-3 Float Upper Trim Point (Span) Value Response Data Bytes BYTE FORMAT DESCRIPTION 0-3 Float Upper Trim Point (Span) Value Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-2 Undefined 3 Error Parameter too large 4 Error Parameter too small 5 Error Too few data bytes 6 Undefined 7 Error 8-15 16 Undefined Error 17-31 32 D-18 Access Restricted Undefined Error 33-127 In write protect mode Busy Undefined Command #178: Write Gas Table Writes the Ultima X Gas Table selection. The Ultima Gas Monitor uses the Gas Table value to select a reference table of linearization values for certain sensors. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Gas Table selection number (see TABLE D-10) Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Gas Table selection number Command-Specific Response Codes CODE CLASS 0 Success 1-2 DESCRIPTION No Command-Specific Errors Undefined 3 Error Parameter too large 4 Error Parameter too small 5 Error 6 7 Error 8-15 16 33-127 In write protect mode Undefined Error 17-31 32 Too few data bytes Undefined Access Restricted Undefined Error Busy Undefined D-19 Command #179: Write Sensor Data Sheet Reset Control Writes a data sheet reset command to Ultima X Gas Monitor. This command causes the Ultima Monitor to reset the current sensor data sheet to factory default settings. This command will set certain device warning status bits and require the user to re-calibrate the sensor. At current, the only valid number for this command is 1. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Sensor reset control Response Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Sensor reset control Command-Specific Response Codes CODE CLASS 0 Success 1-2 DESCRIPTION No Command-Specific Errors Undefined 3 Error Parameter too large 4 Error Parameter too small 5 Error 6 Too few data bytes Undefined 7 Error 8-15 16 Error 17-31 32 D-20 Access Restricted Undefined Error 33-127 In write protect mode Undefined Busy Undefined Command #180: Write Sensor Swap Delay Enable This command writes command number to the Ultima X Gas Monitor to enable or disable the two-minute swap delay feature. This device feature enables a two-minute hold-off of the sensor missing fault, allowing the user to “Swap” or change sensor modules without having the 4-20 mA set to the fault condition. The configuration change bit will be set, and the configuration change counter will be incremented. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Swap Delay 1 = Enable 0 = Disable Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Swap Delay 1 = Enable 0 = Disable Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-2 3 Undefined Error 4 5 Error 6 7 Error 33-127 In write protect mode Undefined Error 17-31 32 Too few data bytes Undefined 8-15 16 Parameter too large Undefined Access Restricted Undefined Error Busy Undefined D-21 Command #181: Write Cal Signal Enable This command writes command number to the Ultima X Gas Monitor to enable or disable the Cal signal output. Without the Cal Signal enabled, the 4-20 mA output will follow the gas reading during calibration. With the Cal Signal enabled, the 4-20 mA output will be set to 3.75 ma during calibration and be held there for one minute after calibration has ended to allow the sensor to re-stabilize. Status group 3 indicates the current setting of this mode. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Cal Signal 1 = Enable 0 = Disable Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Cal Signal 1 = Enable 0 = Disable Command-Specific Response Codes CODE CLASS 0 Success 1-2 DESCRIPTION No Command-Specific Errors Undefined 3 Error 4 Parameter too large Undefined 5 Error 6 Too few data bytes Undefined 7 Error 8-15 16 Error 17-31 32 D-22 Access Restricted Undefined Error 33-127 In write protect mode Undefined Busy Undefined Command #182: Write Calibration Mode This command writes a calibration mode number to the Ultima Gas Monitor. The mode commands initiate a calibration sequence in the device. Device status byte 2 can be monitored to determine the progress of the calibration. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Calibration Mode Number (see TABLE D-11) Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Calibration Mode Number (see TABLE D-11) Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-2 3 Undefined Error 4 5 Undefined Error 6 7 33-127 In write protect mode Undefined Error 17-31 32 Too few data bytes Undefined Error 8-15 16 Parameter too large Access Restricted Undefined Error Busy Undefined D-23 Command #183: Write Calibration Abort This command writes a calibration Abort command to the Ultima Gas Monitor. The calibration abort command instructs the device to suspend the calibration sequence initiated by the calibration mode command. Valid number for this command is 1. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Calibration Abort Command number Response Data Bytes BYTE FORMAT DESCRIPTION 0 Float Calibration Abort Command number Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-2 Undefined 3 Error Parameter too large 4 Error Parameter too small 5 Error Too few data bytes 6 Undefined 7 Error 8-15 16 Undefined Error 17-31 32 D-24 Access Restricted Undefined Error 33-127 In write protect mode Busy Undefined Command #184: Write Calibration Step This command writes a calibration Step Command to the Ultima Gas Monitor. The Step command instructs the device to advance to the next step during a manual calibration sequence. Device status byte 2 can be monitored to determine the progress of the calibration. Valid number for this command is 1. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Calibration Step Number Response Data Bytes BYTE FORMAT DESCRIPTION 0 Float Calibration Step Number Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-2 Undefined 3 Error Parameter too large 4 Error Parameter too small 5 Error Too few data bytes 6 7 Undefined Error 8-15 16 Undefined Error 17-31 32 33-127 In write protect mode Access Restricted Undefined Error Busy Undefined D-25 Command #185: Write Alarm Acknowledge This command writes an Alarm Acknowledge command to the Ultima X Gas Monitor. The alarm acknowledge command instructs the device to clear any latched alarms in the device, provided the setpoint level for the alarm has receded. Valid command number is on 1. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Unsigned Alarm Acknowledge command number Response Data Bytes BYTE FORMAT DESCRIPTION 0 Float Alarm Acknowledge command number Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-2 Undefined 3 Error Parameter too large 4 Error Parameter too small 5 Error Too few data bytes 6-15 16 Undefined Error 17-31 32 Undefined Error 33-127 D-26 Access Restricted Busy Undefined Command #186: Write Protect Mode This command sends a single, unsigned byte to the device. Sending a one puts the device in write protect mode. In write protect mode, all writes and commands are ignored except a command to disable the write protect. Only reads to the device can be made. Sending a disable, releases the device from write protect mode. During write protect mode, all local (Pushbutton) controls are locked out as well. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Write protect Mode (0 = disable, 1 = Enable) Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Write protect Mode (0 = disable, 1 = Enable) Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 2 Error Invalid selection Error Too few data bytes Error In write protect mode Error Access Restricted 3-4 5 Undefined 6 7 Undefined 8-15 16 Undefined 17-31 32 33-127 Undefined Error Busy Undefined D-27 Command #187: Write Alert Option This command disables or enables the Alert Option on the Ultima X unit. This is a single byte containing a 0 if disabled or 1 if enabled. If enabled, the Alert Option will cause the 4-20 mA to be set to 3.75 mA during calibration of an Oxygen sensor (if the Cal Signal Option is also enabled). If the Alert Option is disabled and the Cal Signal enabled, the output will be set to 21 mA during Oxygen sensor calibration. Alert Options ON OFF Calibration Alert relay de-energized Alert relay energized Power on RESET (Countdown) Alert relay de-energized Alert relay energized 4 - 20 CAL mA (Oxygen) 3.75 mA 21 mA 4 -20 POR mA (Oxygen) 3.75 mA 21 mA Request Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Alert Option Mode (0 - disabled, 1 - enabled) Response Data Bytes BYTE FORMAT DESCRIPTION 0 Enum Alert Option Mode (0 - disabled, 1 - enabled) Command-Specific Response Codes CODE CLASS DESCRIPTION 0 2 3 4 5 6 7 8-15 16 17-31 32 33-127 Success No Command-Specific Errors Undefined Parameter too large Undefined Too few data bytes Undefined In write protect mode Undefined Access Restricted Undefined Busy Undefined D-28 Error Error Error Error Error Command #188: Write Relay Normal State This command sets the Ultima X Normal relay state. This is a single byte containing a bit map of the three alarm relays’ non alarm states. Not all gas sensors have on-board relays. Request Data Bytes BYTE FORMAT DESCRIPTION 0 Bit 0 Alarm #1 0 = normally de-energized, 1 = normally energized 0 Bit 1 Alarm #2 0 = normally de-energized, 1 = normally energized 0 Bit 2 Alarm #3 0 = normally de-energized, 1 = normally energized Response Data Bytes BYTE FORMAT DESCRIPTION 0 Bit 0 Alarm #1 0 = normally de-energized, 1 = normally energized 0 Bit 1 Alarm #2 0 = normally de-energized, 1 = normally energized 0 Bit 2 Alarm #3 0 = normally de-energized, 1 = normally energized Command-Specific Response Codes CODE CLASS DESCRIPTION 0 Success No Command-Specific Errors 1-4 5 Undefined Error 6 7 Undefined Error 8-15 16 33-127 In write protect mode Undefined Error 17-31 32 Too few data bytes Access Restricted Undefined Error Busy Undefined D-29 Table D-8. Gas Type Descriptions GAS TYPE DESCRIPTION GAS TYPE CO Carbon Monoxide Performance verified to ANSI/ISA-92.00.01 by FM Approvals DESCRIPTION O2 COMB Oxygen XiIR Infrared Combustible H2S Hydrogen Sulfide Cl Chlorine Cl2 Chlorine Dioxide NH3 Ammonia Combustible-pellistor Performance verified to ANSI/ISA-92.00.01 by FM Approvals Table D-9. Alarm Control Actions Bit0 Alarm Enable 1 = enabled, 0 = disabled Bit1 Alarm Direction 1 = increasing, 0 = decreasing Bit2 Alarm Latch Status 1 = latching , 0 = non-latching Bit3-7 Unused Table D-10. Gas Table Values TABLE DESCRIPTION 1 Methane 2 Propane 3 Ethane 4 n-Butane 5 n-Pentane 6 n-Hexane 7 Cyclopentane 8 Ethylene 21 Acetylene 47 5000 PPM CO2 5% CO2 48 49 50 2% CO2 Custom 250 Unused D-30 Table D-11. Calibration Modes MODE # DESCRIPTION 0 Initiate Zero Sensor sequence 1 Initiate Standard calibration sequence 2 Initiate Initial calibration sequence 3 Initiate Manual (stepped) calibration sequence Table D-12. Sensor Status Codes CODE DESCRIPTION 0x01 Flash Fault 0x05 Ram Fault 0x07 Pellement Fault 0x0A Data Sheet Fault 0x1E Power Fault 0x1F IR Factory Mode 0x20 IR Lamp Fault 0x28 EEPROM R/W Fault 0x2D EEPROM Checksum Fault 0x2F Sensor Missing Fault 0x3A Negative Power Supply Fault 0x3B IR Reference Fault 0x3C Temperature Fault 0x3D IR Analyte Fault 0x3E IR Low Signal Fault 0x3F IR Parameter Fault 0X40 Calibration Fault 0x41 Zero Mode 0x42 Span Mode 0x7C Sleep Mode 0x7D Warm Up Mode 0x7E Power On Reset Mode 0x7F Sensor OK D-31 Performance Typical sampling rates are shown in the following table. Table D-13. Sampling Rates Gas Samples 4 per second PV digital value calculation 5 per second Analog output update 5 per second Power-Up On power-up, the transmitter goes through a self-test procedure (see Chapter 2, "Initial Start-up"), and a sensor warm up and initialization period which takes approximately 30 seconds. During this period, the device will not respond to HART commands, and the analog output is set at 3.75 mA. When the self-test is satisfactorily completed, and the sensor initialized, the PV value is set, and the analog output moves to a value representing the measurement. The rate of this calculation is limited by an internal filter damping time. Only after the PV and SV are correctly set, will the device respond to HART commands. If the self-test fails, all live measurement data (PV, current and percent of range) are set to "Not A Number", and the analog output is set to the configured malfunction-indicating current. The device will attempt to respond to HART commands. Fixed-current mode is cancelled by power loss. Reset Command 42 ("Device Reset") causes the device to reset its microprocessor. The resulting restart is identical to the normal power-up sequence. (See Chapter 2, "Initial Start-up".) Self-Test The self-test procedure is executed at power-up or following Command 42 ("Device Reset"). Some self-test procedures are continuously run in a background mode. The self-test includes: • Microprocessor • RAM D-32 • Program ROM • Configuration storage EEPROM • Sensor communications • Data sheet integrity • Internal communications. This self-test takes about 10 seconds. During self-test, following powerup or reset, the analog output is set to 3.75 mA and the device does not respond to HART commands. During self-test run in background mode, the analog output updates continuously and the device responds normally to HART commands. Continuous self-testing is part of the normal device operation. The same checks are made, but over a longer period between measurement function cycles. Table D-14. Command Response Times Minimum 20 ms Typical 50 ms Maximum 100 ms * * During self-test following a power up reset or reset command, the device may take up to 10 sec to respond. Busy and Delayed-Response The transmitter may respond with "busy" status if a further command is received while self-test or certain command functions are underway. Delayed-response is not used. Long Messages The largest data field used is in the response to Command 21: 34 bytes including the two status bytes. Non-Volatile Memory EEPROM is used to hold the device’s configuration parameters. Both the main board and sensor module contain EEPROM devices. New data is written to this memory on execution of certain write commands, during calibration operations and during normal operation. D-33 Modes Fixed current mode is implemented, using Command 40. This mode is cleared by power loss or reset. Write Protection Write-protection is provided by command 186. When in the Write Protect mode, all read commands are available, no "write" or "command" commands are accepted. Damping Damping is internally-fixed, affecting only the PV and the loop current signal. There is no user-settable damping control. Capability Checklist Table D-15. Capability Checklist Manufacturer, model and revision MSA , Ultima, rev. 2 Device type Transmitter HART revision 7 Device Description available Yes Number and type of sensors 1 Number and type of actuators 0 Number and type of host side signals 1: 4 - 20mA analog Number of Device Variables 13 Number of Dynamic Variables 1 Mappable Dynamic Variables? No Number of common-practice commands 11 Number of device-specific commands 31 Bits of additional device status 32 Alternative operating modes? No Burst mode? Yes Write-protection? Yes D-34 Default Configuration Table D-16. Default Configuration PARAMETER DEFAULT VALUE Lower Range Value 0 Upper Range Value Sensor dependent PV Units Sensor dependent Sensor type various Number of wires 3 Damping time constant N/A Fault-indication jumper Sensor dependent Write-protect mode write enabled Number of response preambles 5 Alarms Enabled ® Calibration Using a HART Communicator Sensor Zero Selection Menu Select Sensor Calibration from the "Sensor Trim" Menu Sensor calibration or “trim” functions are available from several locations in the menu structure. See FIGURE D-8 for a view of this selection menu. First warning screen Once the sensor calibration feature is selected, a warning message displays to indicate that the 4-20 mA output should be disabled from any automatic control loop to prevent false action during calibration. The user must acknowledge this screen to continue. See FIGURE D-9 for a view of this warning screen. Optionally, the user may abort the process at this screen. Second warning screen After acknowledgement of the control loop message, a second warning message displays, informing the user that sensor calibration will be changed. The user can abort the procedure at this time or acknowledge the screen to proceed. See FIGURE D-10 for a view of this screen. Zero Sensor function select screen Upon acknowledgement of the calibration change warning screen, a calibration function selection screen appears. To zero the sensor, select D-35 the “Sensor Zero” function and acknowledge the screen. See FIGURE D-11 for a view of this screen. Calibration initiated screen Once a calibration selection function is selected, the command is sent to the device. A status messages is then returned to indicate the progress. The first status message should indicate that the calibration sequence has started. This screen also shows the sensor value, units and type information. No action is required as it is only a five-second information screen and advances automatically. The user may abort the process at this time. See FIGURE D-12 for a view of this screen. Selection confirmation screen After the initiating screen displays for five seconds, a second information screen displays. This screen displays for five seconds and provides the user confirmation of the current calibration selection. No action is required at this screen, but the user may press the ABORT button to stop the process. See FIGURE D-13 for a view of this screen. Sensor Zero countdown screen Once the information screens are displayed, the device should start sending back a status byte to indicate calibration progress. The first status message should be the 30-second device countdown message. This message prompts user to start applying Zero gas if necessary. This screen also displays the current gas reading from the sensor.(This screen is skipped for the Oxygen sensor as it uses an electronic Zero). This message displays during the 30-second countdown and the user can abort the process at any time. See FIGURE D-14 for a view of this screen message. Zero Adjustment screen After the 30-second countdown screen (or the selection confirmation screen for an Oxygen sensor), the device should send back a status message indicating that the device is attempting to adjust the internal calibration. The user is instructed to apply Zero gas (or room air) at this time. The device waits for a stable reading to occur and then saves the zero calibration data automatically. The user can abort the process at any time by selecting the ABORT button. See FIGURE D-15 for a view of this screen. Calibration completion message Following a successful zero calibration, an information screen displays, indicating the calibration process has completed. This is a five-second, timed message and requires no user input. See FIGURE D-18 for a sample view of this information screen. D-36 Calibration gas reminder screen Once the device has performed a successful Zero function and stored the calibration information, it returns a calibration OK message. This causes a series of calibration closure messages to appear. The first closure message is a reminder to disconnect any calibration gases from the device. See FIGURE D-19 for a sample view of this message screen. The user can abort this screen, but the only affect at this time would be that the last information screen will not display. Loop control reminder message The final information screen following a calibration procedure is a reminder to return the loop to automatic control. See FIGURE D-20 for a sample of this screen. Standard Calibration Procedures Standard Zero/Span Calibration Selection Menu Select Sensor Calibration from the Sensor Trim Menu Sensor calibration or “trim” functions are available from several locations in the menu structure. See FIGURE D-6 for a view of this selection menu. First warning screen Once the sensor calibration feature is selected, a warning message displays to indicate that the 4-20 mA output should be disabled from any automatic control loop to prevent false action during calibration. The user must acknowledge this screen to continue. See section FIGURE D-7 for a view of this warning screen. Optionally, the user may abort the process at this screen. Second warning screen After acknowledgement of the control loop message, a second warning message displays indicating that sensor calibration is changed. The user can abort the procedure at this time or acknowledge the screen to proceed. See FIGURE D-8 for a view of this screen. Standard Calibration function select screen Upon acknowledgement of the calibration change warning screen, the user is presented with a calibration function selection screen. To perform a standard Zero/Span of the sensor, select the “Zero/Span” function and acknowledge the screen. See FIGURE D-9 for a view of this screen. D-37 Calibration initiated screen Once a calibration selection function is selected, the command is sent to the device. A status message is then returned to indicate the progress. The first status message should indicate that the calibration sequence has started. This screen also shows the sensor value, units and type information. No action is required for this screen as it is only a five-second information screen and will advance automatically. The user may abort the process at this time. See FIGURE D-10 for a view of this screen. The red and green LEDs on the main board blink momentarily to indicate the device has begun the procedure. Selection Confirmation Screen After the initiating screen displays for five seconds, a second information screen displays. This screen also displays for five seconds and provides confirmation of the current calibration selection. No action is required at this screen, but the user may press the ABORT button to stop the process. See FIGURE D-11 for a view of this screen. Sensor Zero Countdown screen Once the information screens are displayed, the device should start sending back a status byte to indicate the progress of the calibration. The first status message should be the 30-second device countdown message prompting the user to start applying Zero gas if necessary. This screen also displays the current gas reading from the sensor. (This screen is skipped for the Oxygen sensor, as it uses an electronic Zero). This message displays during the 30-second countdown; the user can abort the process at any time. See FIGURE D-12 for a view of this screen message. The red LED is OFF and the green LED is blinking on the main circuit board to indicate the start of the Zero procedure. Zero Adjustment screen After the 30-second countdown screen (or the selection confirmation screen for an Oxygen sensor), the device should send back a status message indicating that the device is attempting to adjust the internal calibration. The user is prompted to apply Zero gas (or room air) at this time. The device waits for a stable reading to occur and then saves the zero calibration data automatically. The user can abort the process at any time by selecting the ABORT button. See FIGURE D-13 for a view of this screen. Sensor Span countdown screen After successful completion of the sensor Zero procedure, the device automatically steps to the Span routine and displays an information screen indicating the Span procedure has started. This is a 30-second D-38 countdown wait for gas connection and transport. The user is prompted to start applying the Span calibration gas at this time. (For a 0-25% Oxygen sensor, the sensor can be spanned using room air.) See FIGURE D-14 for a sample view of this screen. The red LED is ON solid and the green LED is blinking on the main board to indicate the start of the Span procedure. Adjusting Span screen After the 30-second Span initialization, a Span adjustment screen displays and continually updates with the gas (PV) reading, units and type information. Once the device detects a stable reading, the data is stored automatically and the user is notified of the completion status. See FIGURE D-15 for a sample view of the Span adjustment screen. The user can abort the procedure at any time and the prior calibration data is restored. Calibration completion message Upon successful completion of the SPAN procedure, an information screen displays. See FIGURE D-16 for a sample completion screen. This is a five-second information screen; no user action is required. Calibration gas reminder screen Following the Calibration completion screen, another information screen is presented to inform the user to disconnect any calibration gas from the device. This is a five-second timed message; no user acknowledgement is required. See FIGURE D-17 for a view of this information screen. Loop control reminder message The final calibration screen is an information screen prompting the user to reconnect the sensor output to any automatic control process that was disconnected at the start of the procedure. The user is required to acknowledge this screen. See FIGURE D-18 for a sample view of this screen. D-39 Initial Calibration Procedures Initial Calibration Selection Menu Initial calibration is selected in a manner similar to the standard Zero/Span calibration procedure and the steps are similar (except the function selection should be “Initial Cal”). Initial calibration should be run when a new sensor is connected to the unit or when a standard Zero/Span procedure will not clear a fault condition (such as when the wrong Span gas is used). The Initial Calibration function allows the device to make accurate decisions for the CHANGE SENSOR and CAL FAULT functions. Initial Calibration function select screen Upon acknowledgement of the calibration change warning screen (see "Second warning screen" earlier in this chapter), a calibration function selection screen appears. To perform an Initial Calibration of the sensor, select the “Initial Cal” function and acknowledge the screen. See FIGURE D-4 for a view of this screen. Refer back to "Standard Calibration Procedures" for the complete calibration procedure. User (Stepped) Calibration Procedures User Calibration Selection Menu User calibration is selected in a manner similar to the standard Zero/Span calibration procedure; the steps are similar, except the function selection should be “User Cal”. Normal calibrations are performed and stepped automatically by the device while prompting the user to apply the required calibration gas. This is a timed function and, if the calibration gas is not applied in time or the reading does not stabilize within the given timeout period (windy conditions, duct mount, high sensitivity sensor modules, extended gas sample lines, etc.), it will timeout and send a “Cal Fault” status. User calibration allows the user to manually step through the Zero and Span calibrations and decide when the reading has reached optimum stability. User Calibration step screens User calibration is similar to the standard procedures provided earlier under "Standard Calibration Procedures", except that the automatic adjustment screens described in "Zero Adjustment screen" and "Adjusting Span screen" sections are replaced with a Step/Refresh screen allowing the user to review the readings and decide when to advance the procedure (see FIGURES D-1 and D-2). D-40 Zero cal step screen Figure D-1. Zero cal step screen Span cal step screen Figure D-2. Span cal step screen D-41 Sample Calibration Display Screens HART DDL-based calibration display screens Select Sensor Calibration from the Sensor Trim Menu Figure D-3. Select Sensor Calibration from the Sensor Trim Menu D-42 First warning screen Figure D-4. First Warning screen D-43 Second warning screen Figure D-5. Second Warning screen D-44 Standard Calibration function select screen Figure D-6. Standard Calibration function select screen D-45 Calibration initiated screen Figure D-7. Calibration initiated screen D-46 Selection Confirmation Screen Figure D-8. Selection Confirmation screen D-47 Sensor Zero Countdown screen Figure D-9. Sensor Zero Countdown screen D-48 Zero Adjustment screen Figure D-10. Zero Adjustment screen D-49 Span countdown screen Figure D-11. Span Countdown screen D-50 Adjusting Span screen Figure D-12. Adjusting Span screen D-51 Calibration completion message Figure D-13. Calibration Completion message D-52 Calibration gas reminder screen Figure D-14. Calibration Gas Reminder screen D-53 Loop control reminder message Figure D-15. Loop Control Reminder message Troubleshooting Fault indications Span Fault This fault can occur if the sensor is in cal mode and the required SPAN gas is not applied to the sensor at the indicated time or within the timeout period. The 4-20 mA returns the measured gas value based upon the last successful calibration parameters. This fault sets several status flags in the digital output to indicate that an error has occurred. The current calibration status can be observed by right-clicking on status group 2 to expand it as shown in FIGURE D-16. Other possible cause for a Span Fault could be the use of an incorrect Span gas or improperly set PV Upper Trim point (Span) setting. The Trim (calibration) point information can be viewed from the sensor trim points menu as shown in FIGURE D-17. D-54 Span faults can also be caused by a bad sensor, sensor at end-of-life, or a sensor that is too far out of calibration for the Standard Zero/ Span procedure to make the adjustment. An attempt to Initial Cal the sensor may be able to correct the calibration; otherwise, the sensor must be replaced. Additional sensor status can be obtained by right-clicking on status group 3 to expand it as shown in FIGURE D-18. Calibration status screen Figure D-16. Calibration Status screen D-55 Sensor trim point screen Figure D-17. Sensor Trim Point screen D-56 Additional Sensor status screen Figure D-18. Additional Sensor Status screen Zero Fault The Zero Fault can be caused by a faulty sensor, calibration out of the Standard Zero/Span calibration range, sensor in change, sensor fault or attempting to zero the sensor with Span gas applied. The application of Zero gas should be checked and the sensor status (as defined in FIGURES D-16 and D-18) verified if this fault occurs. D-57 Calibration Aborted User calibration abort or sensor calibration faults can cause a calibration process to abort. Status group 2 as shown in FIGURE D-16 can be viewed to determine if the abort was caused by a cal fault. Status group 2 can be expanded by right-clicking the selection as shown in FIGURE D-19 to provide additional information (also see FIGURE D-16). Device status screen Figure D-19. Device Status screen D-58