MSA ULTIMA X5000 Operating Manual

MSAsafety.com

Operating Manual

ULTIMA® X5000

Gas Monitor

Order No.: 10177361/06

CR 800000042524

For countries of Russian Federation, Republic of Kazakhstan and Republic of Belarus, the gas detector will be delivered with a passport document that includes valid approval information. On the CD with manual instruction attached to the gas detector the user will find the documents "Type Description" and "Test Method" - appendixes to Pattern Approval Certificate of Measuring instrument, valid in the countries of use.

1000 Cranberry Woods Drive Cranberry Township, PA 16066 USA Phone 1-800-MSA-2222 Fax 1-800-967-0398

For your local MSA contacts please go to our website www.MSAsafety.com

Contents

1 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 No Tool Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Bluetooth

2.4 Dual Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5 Retrofit Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6 XCell Sensors Optimized for Fixed Gas Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.7 TruCal Sensing Technology for CO and H

2.8 SafeSwap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.9 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.10 Component Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.11 Label Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.1 Installation Warnings - Read before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.2 Reviewing Shipment and Identifying Product Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3 Product Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.4 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4.1 Sensor Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4.2 Transmitter Mounting Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4.3 Sensor Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.4 Connecting Sensor to Transmitter Housing or Remote Junction Box . . . . . . . . . . . . . . . . . . . . . . 18

3.4.5 Integrated Mounting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.4.6 Mounting Points JB5000 Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4.7 2" (50.8 mm) Pipe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4.8 Adjustable Pipe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4.9 Duct Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.4.10 Mounting with a Sunshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.4.11 Mounting with an SM5000 Sampling Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.5 Installing a Remote Sensor Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.6 Electrical Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6.1 Electrical Warnings - Read before Connecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6.2 Retrofit Applications with UltimaX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6.3 Electrical Hardware Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.6.4 Power Load Requirements and Maximum Mounting Distances. . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.6.5 Instructions for Power and Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.6.6 Relay and Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Wireless Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

S Electrochemical Sensors . . . . . . . . . . . . . . . . . . . . . 9

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.1.2 Sensor Warm Up Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.2 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.2.1 Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.2.2 Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.3 Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.3.1 Life and Health - XCell H

S and CO Sensors with TruCal Only. . . . . . . . . . . . . . . . . . . . . . . . . . . 60

ULTIMA® X5000

. . . . . . . 39

5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.1 Calibration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.2 Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.3 Calibration Frequency for XCell Sensors with TruCal (H

5.3.1 XCell Sensors with TruCal and Diffusion Supervision (H2S & CO only) . . . . . . . . . . . . . . . . . . . . 63

5.3.2 XCell Sensors with TruCal without Diffusion Supervision (H

5.4 Calibration Types: Zero vs. Span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.5 How to Zero Calibrate XCell Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.6 How to Calibrate XCell Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.7 How to Calibrate an Oxygen XCell Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.8 How to Calibrate an XIR PLUS Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.9 XCell Catalytic Bead LOC Over Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.10 Calibration Confirmation and As Found/As Left Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.1 ULTIMA XIR PLUS Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.2 Replacing an XCell Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.3 Clearing a Blockage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

7 Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7.1 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 77

S & CO only). . . . . . . . . . . . . . . . . . . . . 63

S & CO only). . . . . . . . . . . . . . . . . . 63

8 Appendix: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

9 Appendix: Calibration Guide for Additional Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

10 Appendix: General Certification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

11 Appendix: HART Specific Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

ULTIMA® X5000

Safety Regulations

1 Safety Regulations

1.1 Correct Use

The ULTIMA X5000 Gas Monitor, hereafter also called device, is a gas monitor for measuring toxic and combustible gases as well as oxygen. Using sensors, the device tests the ambient air and triggers the alarm as soon as the gas exceeds a specific concentration level.

WARNING!

Read this manual carefully. The device will perform as designed only if it is used, installed, and maintained in accordance with the manufacturer's instructions. Otherwise, it could fail to perform as designed and persons who rely on this device for their safety could sustain serious personal injury or loss of life.

WARNING!

Do not use silicone-type lubricants in assembling the device and do not allow silicone vapors to be drawn into the flow system while in operation. Silicone can desensitize the combustible gas sensor, thereby giving erroneously low readings. 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, alter flameproof/explosion proof characteristics or void agency approvals.

Failure to follow the above warnings can result in serious personal injury or loss of life.

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:

• device may not cause harmful interference, and

• device must accept any interference received, including interference that may cause undesired operation.

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 the user’s expense.

NOTICE

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.

NOTICE

The XCell sensor refers to the sensor portion of the Digital Sensor throughout this manual.

FCC Warning Statements

Changes or modifications not expressly approved by the manufacturer could void the user's authority to operate the equipment.

Industry Canada (IC) Warning Statements

The installer of this radio equipment must ensure that the antenna is located or pointed such that it does not emit RF field in excess of Health Canada limits for the general population; consult Safety Code 6, obtainable from Health Canada's website www.hc-sc.gc.ca.

ULTIMA® X5000

Safety Regulations

1.2 Product Warranty

ITEM WARRANTY PERIOD

MSA warrants that this product will be free from mechanical defects and faulty workmanship for the period specified in this table for each component,

ULTIMA X5000 Gas Monitor

Main Transmitter Housing and PCBA 2 years from date of shipment.

XCell Sensors 3 years from date of shipment.

XIR PLUS 5 years on electronics. 10 years on IR source bulb.

This warranty does not cover filters, fuses, etc. Certain other accessories not specifically listed here may have different warranty periods. This warranty is valid only if the product is maintained and used in accordance with Seller's instructions and/or recommendations. 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 this product. 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.

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 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 replace any nonconforming equipment or parts shall not cause the remedy established hereby to fail of its essential purpose.

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 non-operation of the goods. This exclusion is applicable to claims for breach of warranty, tortious conduct or any other cause of action against seller.

provided it is maintained and used in accordance with MSA's instructions and/or recommendations. Guarantee shall not exceed the indicated warranty period plus six months from the date of manufacture.

ULTIMA® X5000

2 Description

2.1 Display

The ULTIMA X5000 utilizes an Organic LED (OLED) display which is capable of being seen from a distance of up to 50 ft (15 m) depending on conditions. The OLED display provides clear and crisp information in a variety of languages. The gas reading gauge, which wraps around the live reading area, mimics the reading as a percent of full scale and is also used as a progress bar during operations which require a countdown.

Description

Fig. 1 OLED Display

In addition to the OLED display, the ULTIMA X5000 also employs green, yellow and red LEDs on the side and lower middle of its face. These are used to signal normal operating conditions, fault conditions and alarm conditions.

The ULTIMA X5000 will go into “Eco-Mode” after 3 minutes of no interaction and if not in an alarm condition. While in Eco-Mode, the main display will power down and the status LED's will remain illuminated to determine that the device is not in an alarm condition. The OLED display can be powered up by touching either of the two EZ touch buttons on the front display.

ULTIMA® X5000

2.2 No Tool Interface

The ULTIMA X5000 does not require any tools or third party devices to change settings, reset alarms or perform any maintenance feature. The EZ touch buttons work through the glass and do not require opening the explosion proof enclosure. The EZ touch buttons work with bare fingers or with gloved hands, so long as the gloves are not black. The down arrow is used for scrolling, while the right arrow is used for selecting options. See section 4 for more information on navigating the menu with the EZ touch buttons.

Fig. 2 ULTIMA X5000 Interface

2.3 Bluetooth® Wireless Technology

The ULTIMA X5000 can be ordered with Bluetooth communication. Using the X/S Connect App on an appropriate smart phone or tablet, you are able to interface with the ULTIMA X5000 in a larger and more user friendly setting. Connecting via Bluetooth enables communication with transmitter up to 70 feet (21 m) away.

Description

WARNING!

Bluetooth Operation is dependent upon signal availability of the wireless service(s) necessary to maintain the communication link. Loss of wireless signal will prevent communication of alarms and other information to linked devices. Take appropriate precautions in the event a loss of wireless signal occurs.

Failure to follow the above warning can result in serious personal injury or loss of life.

If the device was not ordered with Bluetooth it cannot be upgraded.

If ordered with Bluetooth, the device will be shipped with Bluetooth enabled. See section 4 for instructions on disabling Bluetooth.

The ULTIMA X5000 and user provided communication device will need to be paired. This requires both devices to be in range and for a pairing sequence inputting a 6 digit pairing code. The instructions will be displayed on both the ULTIMA X5000 and communication device.

There are communication devices capable of being used in classified areas. Please contact your MSA representative for additional information.

2.4 Dual Sensing

The ULTIMA X5000 is capable of communicating with and displaying information for two sensors at a time. There are no restrictions to the type of sensors connected to the device.

The ULTIMA X5000 Gas Monitor generates two discrete analog outputs; one for each sensor connected to the transmitter. The analog output associated with Sensor 1 also has the digital HART (Highway Addressable Remote Transducer) communication superimposed on the analog signal. If two sensors are connected, the digital HART communication carries information for both sensors.

ULTIMA® X5000

2.5 Retrofit Installations

The ULTIMA X5000 has the conduit entries located in the exact same orientation and distance from the wall and the mounting holes for attaching to a wall are identical to the Ultima X.

2.6 XCell Sensors Optimized for Fixed Gas Applications

XCell toxic and combustible cat bead sensors are developed and manufactured by MSA. Now optimized for fixed gas applications, the XCell sensor platform is available in the ULTIMA X5000 and provides multiple benefits, including a standard 3-year warranty on all XCell sensors.

One important optimization for fixed gas was incorporating the GM catalytic bead into the XCell sensor. The XCell Oxygen sensor does not use lead, but rather a non-consuming reaction chemistry. The XCell Oxygen sensor is expected to last well over 3-years and can be safely stored on the shelf for at least 1 year without sensor performance degradation. Changes in barometric pressure across the range of 86 kPa - 108 kPa have a negligible effect on the operation of the sensor.

2.7 TruCal Sensing Technology for CO and H

Using patented pulse check technology and proprietary Adaptive Environmental Compensation (AEC) algorithms, all XCell sensors with TruCal verify operation by actively adjusting the sensor output for changes in sensitivity. Some XCell sensors with TruCal also include Diffusion Supervision, which monitors the sensor inlet for obstructions that could prevent gas from reaching the sensor.

Every six hours, an electrical pulse stimulates the XCell sensor similar to having actual calibration gas applied, providing a snapshot of the sensor’s sensitivity at the time of the pulse. Using this sensitivity snapshot, the sensor can diagnose sensor failures like electrode poisoning, electrolyte leaking, or electrical connectivity issues. AEC uses the sensitivity snapshots provided by the pulse check to adjust sensor output, compensating for environmental impacts on sensor accuracy. If the AEC adjustment is greater than expected based on typical environmental impact variations, the transmitter LED’s will slowly flash GREEN, alerting users that the sensor should be calibrated to reset the AEC cycle. Users can also enable a Calibration Alert function that will send a milli-amp signal on the analog output to the control room. The result is a sensor that actively self-monitors for operation and accuracy, with far fewer manual calibrations. Diffusion supervision actively monitors the sensor inlet for obstructions. If an obstruction is detected, the sensor will go into a fault mode to alert users and the control room that it is not seeing gas due to an obstruction. Objects residing directly on or in the sensor inlet that result in a significant impact to the gas path are very likely to be detected by Diffusion Supervision. Examples include paint, tape, water, and dirt. Small amounts of these materials can be visible on the inlet while not impacting the gas path enough to trigger a Diffusion Supervision Fault. A fault signal will only be sent out when the system determines that the amount of material that has accumulated on or inside the sensor inlet is negatively affecting the gas path.

Actual TruCal sensor performance will depend on the application, background gas exposure, and environment. To validate XCell sensors with TruCal, it is recommended that users follow their regular calibration cycle and record the “as found” and “as left” values. This data can be used to extend the time between calibrations depending on the required specification of the application.

S Electrochemical Sensors

Description

ULTIMA® X5000

2.8 SafeSwap

The ULTIMA X5000 comes with patented SafeSwap technology, which allows users to change or replace XCell sensors without needing to power down the instrument. For added convenience, the ULTIMA X5000 comes with Swap Delay enabled by default; a feature that gives users a 2 minute window to change sensors without triggering a fault condition. For more information on SafeSwap and Swap Delay, see section 4.2.1.

WARNING!

 As part of the product certification, it was verified that optional communication functions of this

gas detection instrument while operating at the maximum transaction rate do not adversely affect the gas detection operation and functions of the instrument. The product certification, however, does not include or imply approval of the SafeSwap feature, communications protocol or functions provided by the software of this instrument or of the communications apparatus and software connected to this instrument.

 Follow the warnings below when removing or replacing sensors. Reference 2.10 for compo-

nent overview.

- Never remove or replace a Sensor Body Assembly or an Ultima XIR Plus while under power or when explosive hazards are present.

- Confirm that the area is free of explosive hazards before removing or replacing an XCell Sensor under power.

- To remove an XCell Sensor, unscrew XCell Sensor three full turns, wait 10 seconds, and then remove the XCell Sensor completely.

Description

Failure to follow the above warnings can result in serious personal injury or loss of life.

2.9 Housing

The ULTIMA X5000 comes in 316 Stainless Steel for the highest corrosion resistance. Both ¾” NPT and M25 conduit entries are available. To attach a sensor to an M25 housing, an M25 adapter is required and will be included with the shipment. An integral surface mount bracket can be used to mount directly into the wall surface or used with a U-Bolt for mounting to a 2” pipe. Custom tags are available and easily attach to an integral ring.

ULTIMA® X5000

2.10 Component Overview

Description

Fig. 3 Component Overview

* Only used with M25 bases

2.11 Label Overview

Serial number is located where shown (highlighted in green). Actual number of digits may be different.

Fig. 4 Serial Number Label

ULTIMA® X5000

Description

Fig. 5 Transmitter - Position of Labels

Fig. 6 Board Stack - Position of Labels

ULTIMA® X5000

Fig. 7 Digital Sensor - Position of Labels

Description

Fig. 8 XIR Plus - Position of Labels

ULTIMA® X5000

3 Installation

3.1 Installation Warnings - Read before Installation

WARNING!

 Refer to manual addendum (Part Number 10182779) for Certification Information and addi-

tional safety information before installation and operation.

 Some Digital Sensors are provided in a fritless sensor housing. The fritless sensor housing is

labeled as Div 2 or Zone 2 and is approved for Div 2 or Zone 2 installations only. The protection method is Non-incendive or Type n respectively. Ensure all components are approved for the wiring method being used and in accordance with the National Electrical Code of the country of use, any applicable local regulations, this manual and the addendum to the manual.

 As part of the product certification, it was verified that optional communication functions of this

 Follow the warnings below when removing or replacing sensors. Reference Fig. 3 for compo-

nent overview.

- Never remove or replace a Sensor Body Assembly or an Ultima XIR Plus while under power or when explosive hazards are present.

- Confirm that the area is free of explosive hazards before removing or replacing an XCell Sensor under power.

- To remove an XCell Sensor, unscrew XCell Sensor three full turns, wait 10 seconds, and then remove the XCell Sensor completely.

 Plug all unused conduit entries with a suitably certified blanking/stopping plug.  Do not paint the device. Avoid painting in areas where the ULTIMA X5000 and remote sensor

junction box are located. If painting is required in an area where an ULTIMA X5000 or remote sensor has been installed, exercise caution to ensure paint is not deposited on the sensor inlet fitting. Paint solvents can also cause an alarm condition to occur or potentially poison electrochemical sensors.

 The H

- Alcohols (methanol, ethanol, isopropanol)

- Nitrogen dioxide (NO

- Chlorine (Cl

- Paint solvents (acetone, turpentine, toluene, mineral spirits, etc.)

 The CO Digital Sensor may be adversely affected by the following substances:

- Alcohols (methanol, ethanol, isopropanol)

- Paint solvents (acetone, turpentine, toluene, mineral spirits, etc.)

 The O

- Long term exposure to low levels of Acetylene

- Paint solvents (acetone, turpentine, toluene, mineral spirits, etc.) in high concentrations larger than 1000 ppm or prolonged exposure to lower concentrations

 Prolonged exposure of the H

in gas measurement readings of H present.

 It is not recommended to expose the O

containing Oxygen levels above 30% (v/v) or below 5% (v/v). The O concentrations below 5% (v/v) but not for prolonged periods of time.

 Protect the device from extreme vibration.  Do not mount the sensing head in direct sunlight without a sunshield (Part Number 10180254).  The ULTIMA XIR PLUS Sensor contains no user- or field-serviceable parts and must be

returned to the factory for repair. Any attempt to open the sensor will damage the unit and void the warranty.

S Digital Sensor may be adversely affected by the following substances:

)

Digital Sensor may be adversely affected by the following substances:

S Digital Sensor to humidity levels of 5% RH or lower will result

S that are greater than the actual gas concentration

, H2S and CO Digital Sensors to environments

sensor will operate at

Installation

Failure to follow the above warnings can result in serious personal injury or loss of life.

ULTIMA® X5000

NOTICE

When installing the XIR PLUS sensor, under no circumstances should a pry-bar be applied to the two legs that support the unit's reflectors during installation or removal of the sensor. Applying force to the legs can permanently damage the XIR PLUS sensor.

3.2 Reviewing Shipment and Identifying Product Model

To determine your sensor type and options, check the shipping carton.

Installation

Fig. 9 Shipping Label

The device is not shipped with the sensors attached to the housing. The XIR PLUS is a one piece sensor, but all other sensors are comprised of two parts; the Sensor Body Assembly and the XCell Sensor. Check the sensor details before attaching to the device housing to ensure that the correct sensor type is being installed. The sensor details are listed on the inside of the XCell Sensor. Unscrew the XCell Sensor from the Sensor Body Assembly and check the label on the inside for gas type, range, replacement ATO configuration, serial number, and firmware revision number.

3.3 Product Installation Check List Before Installation

• Review national electrical codes

• Review local procedural and building codes

• Determine optimum transmitter placement

• Determine wire requirements

• Determine mounting hardware requirements

• Review approvals and ensure suitability for installation

Mounting

• Attach appropriate sensor to housing or junction box (see section 3.4.3 for proper sensor orien-

tation)

• Mount transmitter or junction box using appropriate mounting hardware

• Confirm free air flow around the sensor

ULTIMA® X5000

3.4 Mounting

WARNING!

Refer to manual addendum (Part Number 10182779) for Certification Information before installation.

Some toxic gases are provided in a fritless sensor housing. The fritless sensor housing is labeled as Div 2 or Zone 2 and is approved for Div 2 or Zone 2 installations only. The protection method is Nonincendive or Type n respectively. Ensure all components are approved for the wiring method being used and in accordance with the National Electrical Code of the country of use, any applicable local regulations, this manual and the addendum to the manual.

Failure to follow the above warnings can result in serious personal injury or loss of life.

3.4.1 Sensor Mounting Location

The best location for the transmitter and the sensor may not be the same location. Sensors should be placed in a location where a gas leak is most likely to be detected. When the best sensor placement would not allow the transmitter display to be easily viewed or accessed, a remote junction box can be used to mount the sensor remotely from the transmitter, allowing both to be installed in the optimum location.

Two main factors should be considered when choosing a sensor location. The first is the density of the target gas relative to the air. Gases, such as propane, that are heavier than air should be placed near ground level while gases that are lighter than air should be placed above potential leak sources.

Optimum sensor placement will depend on the surrounding processing equipment, such as pipes, valves, or turbines. MSA offers a gas and flame mapping service that systematically evaluates potential sources of leaks and recommends detector quantity and placement to create the most effective detection system.

3.4.2 Transmitter Mounting Location

The transmitter display should be mounted so that the screen is visible and easily accessed after installation. 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 and to provide maximum flexibility for using conduit entries.

Installation

ULTIMA® X5000

3.4.3 Sensor Orientation

WARNING!

Mount the XIR PLUS with the sensor inlet fitting extended horizontally from the main enclosure (Fig. 10) to prevent the build-up of particulate or liquid matter on the monitor's optical surfaces.

Mount the digital sensor with the sensor inlet fitting (Fig. 11) pointed downward; otherwise, the inlet may become clogged with particulate matter or liquids.

Failure to follow the above warnings may result in serious personal injury or loss of life.

Sensor orientation will depend on the sensor type. If mounting an ULTIMA XIR PLUS sensor, whether locally on the transmitter or via remote junction box, the sensor should be mounted horizontally. If the ULTIMA XIR PLUS sensor is not mounted horizontally, the sensor will be prone to more frequent beam blocking issues due to accumulated dust and condensation on the surface of the ULTIMA XIR PLUS sensor. Fig. 10 shows the correct and incorrect mounting orientations for the ULTIMA XIR PLUS.

Installation

Fig. 10 Correct and Incorrect Mounting Orientations for ULTIMA XIR PLUS Sensor

All other sensors including electrochemical, combustible catalytic bead, and oxygen sensors should be mounted vertically, with the gas inlet pointed downward. If the sensor is not mounted with the gas inlet facing down, it is more likely to become clogged with particulate matter or liquids. Fig. 11 shows the correct and incorrect mounting orientation for digital sensors.

Fig. 11 Correct and Incorrect Mounting Orientation for Digital Sensors

ULTIMA® X5000

3.4.4 Connecting Sensor to Transmitter Housing or Remote Junction Box

Sensors are not shipped attached to the main enclosure or junction box. All sensor modules interface with the transmitter via a digital four-terminal connection. Up to two sensors can be connected to a single transmitter, with each sensor getting a dedicated analog (4-20 mA) output.

Consider the sensor dimensions when choosing a mounting location for the transmitter or junction box.

To connect the sensor:

(1) Turn the transmitter or junction box lid counterclockwise to remove

(2) Pull on the metal bail to remove the board stack and expose wiring connections.

(3) Route the cable from the sensor through a conduit entry hole in the enclosure so that the

sensor is oriented in the correct position (see section 3.4.3 for details).

(Repeat to attach a second sensor to the ULTIMA X5000 transmitter).

(4) Connect the sensor to the "Sensor 1" position on the electronics assembly.

a) If using a second sensor, connect it to the “Sensor 2” position.

NOTICE

If only using one sensor, and it is connected to “Sensor 2” position, the ULTIMA X5000 will enter Sensor Missing fault. See Disable Sensor in section 4.2.2 for details on how to clear this fault.

Installation

Fig. 12 Connecting Sensor to the Stack

Note: Sensor connectors come pre-wired on the sensor body.

ULTIMA® X5000

Fig. 13 Grounding Sensor to Transmitter Housing

(5) Verify the sensor connector is firmly seated on the terminal board.

Installation

(6) Attach the sensor's ground to either of the grounding screws inside the ULTIMA X5000

housing.

(7) Replace the board stack legs into the four depressions in the housing. Push firmly on the

board stack where indicated (see Fig. 14).

Fig. 14 Highlighted Areas Show Where to Press when Replacing a Board Stack

NOTICE

Avoid pressing on the left and right areas where the LEDs are located. Pressing directly on the display will damage the display and will void the warranty. Ensure that the electronics assembly is fully engaged in the mounting holes. If not fully seated, the user interface buttons may not function properly.

(8) Replace the cover by turning clockwise.

ULTIMA® X5000

3.4.5 Integrated Mounting Points

The ULTIMA X5000 transmitter can be surface mounted without any additional brackets using the integrated mounting tabs.

Fig. 15 Internal Mounting Tabs (not compatible with ULTIMA XIR PLUS Sensors)

An supplementary mounting bracket is required for surface mounting the ULTIMA X5000 with an attached ULTIMA XIR PLUS sensor.

Installation

Fig. 16 Mounting Bracket for ULTIMA X5000 (compatible with ULTIMA XIR PLUS Sensors)

ULTIMA® X5000

3.4.6 Mounting Points JB5000 Junction Box

The JB5000 junction box can be mounted directly using the 4 integrated 10-32 threaded holes on the back of the enclosure or with the use of a mounting bracket (Part Number 10206570).

Fig. 17 JB5000 bracket attachment

3.4.7 2" (50.8 mm) Pipe Mount

The integrated mounting tabs on the device housing can be mounted to a 2" (50,8 mm) pipe using a standard U-bolt. MSA provides U-bolts as an optional accessory (Part Number 10179873), however any 2” (50.8 mm) pipe U-bolt rated for the weight and dimensions of the ULTIMA X5000 can be used.

Installation

Fig. 18 2" Pipe Mount with U-Bolt

ULTIMA® X5000

3.4.8 Adjustable Pipe Mount

A Universal Pipe Mount Kit (Part Number 10176946) can be used to mount the ULTIMA X5000 on pipes ranging from 1-6” (20-150 mm) in diameter. Two brackets are mounted over top of the integrated mounting tabs and fitted with an adjustable pipe band (not included).

Installation

Fig. 19 Adjustable Pipe Mount

ULTIMA® X5000

3.4.9 Duct Mount

Duct mount kits are available for monitoring atmosphere inside flat or round ducts. Round duct mount kits are available for small ducts 12-20" (305-508 mm) in diameter (Part Number

10179124) and large ducts 20-40" (508-1016 mm) in diameter (Part Number 10179321). The flat duct mount (Part Number 10176947) is universal for flat ducts.

NOTICE

Consider the sensor type before choosing a duct mount location. ULTIMA XIR Plus sensors should be mounted horizontally and all other sensors should be mounted vertically.

NOTICE

Air flow in the duct must be zero to ensure proper calibration.

Installation

Fig. 20 Flat Duct Mount

Fig. 21 Round Duct Mount

ULTIMA® X5000

3.4.10Mounting with a Sunshield

A sunshield is required to protect the ULTIMA X5000 from direct sun light (Part Number 10180254). The sunshield can be used in any of the mounting configurations.

Installation

Fig. 22 Sunshield with Wall Mounting Bracket

Fig. 23 Sunshield with Universal Pipe Mount

ULTIMA® X5000

3.4.11Mounting with an SM5000 Sampling Module

An aspirated (PN 10058101) and a DC pump (PN 10043264) model are available for use with the X5000 with either digital or XIR sensors. For more information on mounting requirements and use with SM5000 sampling modules, see the SM5000 operating manual(s).

Installation

Fig. 24 Mounting the SM5000 with Digital Sensor

Fig. 25 Mounting the SM5000 with XIR PLUS Sensor

SM5000 is not for sale in EU.

Diffusion Supervision must be disabled when using the SM5000

ULTIMA® X5000

3.5 Installing a Remote Sensor Junction Box

Sensors mounted remotely must use the ULTIMA X5000 junction box. Only one sensor can be connected to each junction box. The junction box housing is the same construction as the ULTIMA X5000 transmitter. The mounting options and instructions for connecting the sensor are the same for sensors connected directly to the ULTIMA X5000 transmitter housing. The junction box is available in 316 Stainless Steel.

Sensors can be remoted up to 328 ft (100 m) from the transmitter housing, as long as the ULTIMA X5000 transmitter is mounted within maximum distance from the power supply, as indicated in tables in section 3.6.4. The junction box does not have an illuminated display and has two connectors: a single sensor input and an output connecting to the transmitter. A 16 AWG (1.31mm

) 4 element cable with a braided shield should be used for the electrical connection between the junction box and the ULTIMA X5000 transmitter. Specific cable recommendations are Alpha wire 3248 or equivalent.

The X5000 junction box must be used for remote XIR PLUS sensors. The use of third party junction boxes may void product warranty.

Installation

Fig. 26 Junction Box

Fig. 27 Junction Box Electrical Connections

ULTIMA® X5000

If the remote sensor is not easily accessed, it is best practice to install tubing that can be used to apply calibration gas from the device display. Route the tubing to the ULTIMA X5000 Gas Monitor, ensuring that there are no kinks, leaks or other obstructions. Secure this tubing near the monitor.

3.6 Electrical Power Connections

3.6.1 Electrical Warnings - Read before Connecting Power

WARNING!

 Before wiring the ULTIMA X5000 transmitter, disconnect the power source supplying the trans-

mitter and ensure no hazardous atmosphere present; otherwise, electrical shock or ignition of a hazardous atmosphere could occur.

 Install wiring in accordance with the electrical code of the country in use, the local authority

having jurisdiction and these installation instructions, as applicable.

 Do not make any connections to the ULTIMA X5000 main board or junction box input, output,

and relay connections while under power. Making connections under power could lead to electrical shock or ignition of a hazardous atmosphere.

 ULTIMA X5000 with relays are not approved for non-incendive wiring methods. Use of non-

incendive wiring methods could lead to ignition of a hazardous atmosphere.

 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.

 The internal grounding terminal located in the base of the transmitter 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.

 As part of the product certification, it was verified that optional communication functions of this

 Follow the warnings below when removing or replacing sensors. Reference Fig. 3 for compo-

nent overview.

- Never remove or replace a Sensor Body Assembly or an Ultima XIR Plus while under power or when explosive hazards are present.

- Confirm that the area is free of explosive hazards before removing or replacing an XCell Sensor under power.

- To remove an XCell Sensor, unscrew XCell Sensor three full turns, wait 10 seconds, and then remove the XCell Sensor completely.

Installation

Failure to follow the above warnings can result in serious personal injury or loss of life.

3.6.2 Retrofit Applications with UltimaX

The Ultima X5000 was designed to be easily retrofitted with existing UltimaX wiring. When replacing an existing UltimaX with the equivalent X5000 sensor technology, the following items need to be checked in order for the X5000 to operate:

1) Wire gauge needs to be 18-14 AWG

2) Sufficient power must be supplied to the X5000 in accordance with the maximum wire lengths.

(See tables 1-6) If these requirements are met, performance of the X5000 should meet the noise immunity standard equivalent of the UltimaX using the existing wiring; However, the installation may not meet the latest EMC EN50270 noise immunity standard that the X5000 meets with the grounding and wiring scheme as indicated in I/O drawing SK3015-1051.

ULTIMA® X5000

3.6.3 Electrical Hardware Requirements

Braided shielded, twisted pair, instrument quality wire or cable should be used to minimize the possibility of noise interference and contact with other voltages. Selection of shielded cable must comply with local requirements.

Conduit, in addition to braided shielded wire, may also be needed in areas where large amounts of electrical noise is expected. All cable shields should be terminated to earth ground at one end only.

The ULTIMA X5000’s (RED) power connector terminals can accommodate up to 14 AWG (2.08 mm Incoming power and signal cables should be a braided shield cable such as Alpha Wire 3248 or equivalent. The braided shield must be terminated to the instrument housing with a 360 degree connection to earth ground as shown in Fig. 31 or alternatively, the earth ground at the user’s power source location.An external Class 2 power supply is required to supply 11-30 VDC to the ULTIMA X5000. Incoming power and signal cables should be a braided shield cable such as Alpha Wire 3248 or equivalent.

). Four conductors are also required for the ULTIMA X5000 remote junction boxes.

Installation

ULTIMA® X5000

3.6.4 Power Load Requirements and Maximum Mounting Distances

Consider future needs when selecting cable size and power supply. The maximum distance between the X5000 transmitter and the power supply depends on the sensor configuration (sensing technology and one or two sensors), wire gauge, and the power supply voltage.The tables below outline the maximum transmitter mounting distances. First determine if the sensor(s) will be locally or remotely mounted. Then choose sensor type(s). The corresponding nominal maximum power and mounting distances by wire gauge are shown.

SEE TABLE 1 & 2

24V DC

X5000

SENSOR 1

Installation

SEE TABLE 1 & 2

24V DC

Fig. 28 Single Sensor

Sensor Mounting Sensor 1

Echem 2.8 2211 3337 5314 8440

Mounted on transmitter

Catalytic 4.9 1548 2335 3719 5907

XIR PLUS 6.7 1184 1787 2846 4520

Remote mounted on junction box (up to 328 ft)

Echem 2.8 2210 3335 5313 8439

Catalytic 4.9 1504 2294 3679 5867

XIR PLUS 6.7 1090 1697 2759 4435

Max. Power (W)

328 ft MAX

X5000

JUNCTION

BOX

SENSOR 1

Max. Distance (ft) to transmitter

24 VDC Supply

18 AWG 16 AWG 14 AWG 12 AWG

Tab. 1 Maximum Wire Length to Main Transmitter with Single Sensor, Imperial Units

When sizing a system's 24 V supply, a 1 A inrush current with a 1 ms duration should be considered for each ULTIMA X5000 on the power supply.

Assumes transmitter was ordered with relays

ULTIMA® X5000

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