MSA Ultima MOS-5 User manual

The information and technical data disclosed in
this document may be used and disseminated
only for the purposes and to the extent
specifically authorized in writing by MSA.
Instruction Manual 04-14
MSA reserves the right to change published
specifications and designs without prior notice.
MANMOS5
Part No. MANMOS5
Revision 1
Ultima® MOS-5
Intelligent Sensor for
Hydrogen Sulfide Gas Detection

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Table of Contents
TABLE OF FIGURES..................................................................................................................VI
TABLE OF TABLES...................................................................................................................VII
QUICK START GUIDE.................................................................................................................1
Mounting and Wiring...............................................................................................................................1
Tools Required ……..…………………………………………………………………………………………...1
Terminal Connections.............................................................................................................................1
1.0 INTRODUCTION ....................................................................................................................4
1.1 Protection for Life.......................................................................................................................4
1.2 Special Warnings.......................................................................................................................4
1.3 System Integrity Verification ......................................................................................................5
2.0 PRODUCT DESCRIPTION.....................................................................................................7
2.1 General Description ...................................................................................................................7
3.0 INSTALLATION......................................................................................................................8
3.1 Receipt of Equipment.................................................................................................................8
3.2 Tools Required...........................................................................................................................8
3.3 Choosing Product Locations......................................................................................................8
3.3.1 Remote Mounting of the Sensor from the Electronics..................................................9
3.4 Mounting and Wiring................................................................................................................10
3.5 Terminal Connections..............................................................................................................11
3.5.1 Terminal Block TB1 – Sensor Connections................................................................11
3.5.2 Terminal Block TB2 – Power and Signal Connections...............................................12
3.5.3 DC Power and Ground Connections...........................................................................13
3.5.4 Analog Signal Connections.........................................................................................13
3.5.5 Terminal Block TB3 – Relay Connections ..................................................................14
3.5.6 European Union (EU) Approved Applications.............................................................15
3.5.7 Cable Termination in the Non-hazardous Area ..........................................................15
3.6 Maintaining the X/P Integrity....................................................................................................15
4.0 OPERATION.........................................................................................................................17
4.1 Start-Up Checklist....................................................................................................................17
4.2 Start-Up....................................................................................................................................17
4.3 Relay Reset..............................................................................................................................17
4.4 User Selectable Options ..........................................................................................................18
4.4.1 Ultima MOS-5 Intelligent Sensor User Menu Structure..............................................19
4.4.2 Sensor Range.............................................................................................................19
4.4.3 Calibration Output.......................................................................................................20
4.4.4 Warning Relay Settings ..............................................................................................20
4.4.5 Alarm Relay Settings...................................................................................................21
4.4.6 Modbus Channel 1 Settings........................................................................................21
4.4.7 Modbus Channel 2 Settings........................................................................................22

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4.5 HART........................................................................................................................................22
4.6 Gas Check Mode .....................................................................................................................23
4.6.1 Procedure for Checking the Calibration......................................................................23
4.7 Calibration................................................................................................................................24
4.7.1 Calibration Procedure .................................................................................................24
4.7.2 Aborting Calibration.....................................................................................................25
4.7.3 Remaining Sensor Life................................................................................................25
4.7.4 Initializing the Remaining Sensor Life.........................................................................26
4.8 Calibration Equipment..............................................................................................................26
4.8.1 Calibrating with a Breaker Bottle and Ampoules ........................................................26
4.8.2 Calibrating with an H2S Portable Purge Calibrator .....................................................26
5.0 MAINTENANCE ...................................................................................................................28
5.1 General Maintenance...............................................................................................................28
5.2 Storage.....................................................................................................................................28
6.0 TROUBLESHOOTING .........................................................................................................29
6.1 Fault Codes and Their Remedies............................................................................................29
6.1.1 F2 - Failed to Complete the Calibration......................................................................29
6.1.2 F3 Flash Checksum Error...........................................................................................29
6.1.3 F4 - Sensor Heater Open Error or Sensor Amplifier Error..........................................29
6.1.4 F5 - Sensor Heater Shorted Error...............................................................................30
6.1.5 F6 - Low Supply Voltage.............................................................................................30
6.1.6 F7 - EEPROM Verification Failure..............................................................................30
6.1.7 F8 - Failure to Complete Setup...................................................................................30
6.1.8 F9 - Gas Check Period Exceeded ..............................................................................31
6.1.9 F10 – Switch Error ......................................................................................................31
6.1.10 F11 Internal Error........................................................................................................31
7.0 CUSTOMER SUPPORT.......................................................................................................32
7.1 MSA Office...............................................................................................................................32
8.0 MODBUS INTERFACE ........................................................................................................33
8.1 Baud Rate................................................................................................................................33
8.2 Data Format.............................................................................................................................33
8.3 Modbus Read Status Protocol (Query/Response)...................................................................33
8.3.1 Modbus Read Query Message...................................................................................33
8.3.2 Modbus Read Response Message.................................................................................35
8.4 Modbus Write Command Protocol (Query/Response) ............................................................35
8.4.1 Modbus Write Query Message ...................................................................................35
8.4.2 Modbus Write Response Message.............................................................................35
8.5 Function Codes Supported ......................................................................................................36
8.6 Exception Responses and Exception Codes...........................................................................36
8.6.1 Exception Response...................................................................................................36
8.6.2 Exception Code...........................................................................................................37
8.7 Ultima MOS-5 Intelligent Sensor Command Register Locations.............................................38
8.8 Ultima MOS-5 Intelligent Sensor Command Register Details .................................................41
8.8.1 Analog (00H)...............................................................................................................41
8.8.2 Mode (01H).................................................................................................................41
8.8.3 Status/Error (02H).......................................................................................................41

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8.8.4 Not Used (03H)...........................................................................................................42
8.8.5 Unit Type (04H)...........................................................................................................42
8.8.6 Software Revision (05H).............................................................................................42
8.8.7 Status Block (06H)......................................................................................................42
8.8.8 Analog Value (06H).....................................................................................................42
8.8.9 Mode & Error (07H).....................................................................................................42
8.8.10 Error Sensor & Sensor Life (08H)...............................................................................42
8.8.11 Display (0x09H & 0x0AH)...........................................................................................43
8.8.12 Serial Number (0BH/0CH) ..........................................................................................43
8.8.13 Alarm Settings (0DH)..................................................................................................43
8.8.14 Warn Settings (0EH)...................................................................................................44
8.8.15 Com1 Address (0FH)..................................................................................................44
8.8.16 Com1 Baud Rate (10H) ..............................................................................................44
8.8.17 Com1 Data Format (11H) ...........................................................................................45
8.8.18 Com2 Address (12H) ..................................................................................................45
8.8.19 Com2 Baud Rate (13H) ..............................................................................................45
8.8.20 Com2 Data Format (14H) ...........................................................................................45
8.8.21 Not Used (15H)...........................................................................................................46
8.8.22 Reset Alarms (16H).....................................................................................................46
8.8.23 Sensor Life (17H)........................................................................................................46
8.8.24 Sensor Scale (18H).....................................................................................................46
8.8.25 MODEL 10K Controller (Co – Calibration Output) (19H)..........................................46
8.8.26 Not Used (1A, AB, 1C H) ............................................................................................46
8.9 HART Enable (1D H)................................................................................................................46
8.9.1 HART Test (1Eh).........................................................................................................46
8.9.2 Abort Calibration (1Fh)................................................................................................47
8.9.3 Total Receive Errors (20H) .........................................................................................47
8.9.4 Bus Activity Rate % (21H)...........................................................................................47
8.9.5 Function Code Errors (22H)........................................................................................47
8.9.6 Starting Address Errors (24H).....................................................................................47
8.9.7 RXD CRC Errors Hi (25H) ..........................................................................................47
8.9.8 RXD CRC Errors Lo (Same as Hi) (26H)....................................................................47
8.9.9 Parity Errors (27H)......................................................................................................47
8.9.10 Overrun Errors (28H) ..................................................................................................48
8.9.11 Framing Errors (29H)..................................................................................................48
8.9.12 Total Software CH1 Errors (2AH) ...............................................................................48
8.9.13 Not Used (2BH)...........................................................................................................48
8.9.14 Clear Hardware Errors (2CH) .....................................................................................48
8.9.15 Clear Communication Errors (2DH)............................................................................48
8.9.16 User Information (60H to 6FH)....................................................................................51
8.9.17 CH2 Total Receive Errors (70H).................................................................................52
8.9.18 CH2 Bus Activity Rate % (71H) ..................................................................................52
8.9.19 CH2 Function Code Errors (72H)................................................................................52
8.9.20 CH2 Starting Address Errors (73H) ............................................................................52
8.9.21 CH2 Number of Register Errors (74H)........................................................................52
8.9.22 CH2 RXD CRC Errors Hi (75H)..................................................................................52
8.9.23 CH2 RXD CRC Errors Lo (Same as Hi) (76H) ...........................................................52
8.9.24 CH2 Parity Errors (77H).............................................................................................52
8.9.25 CH2 Overrun Errors (78H)..........................................................................................52
8.9.26 CH2 Framing Errors (79H)..........................................................................................53
8.9.27 CH2 Total Software CH1 Errors (7AH).......................................................................53
8.9.28 Not Used (7BH)...........................................................................................................53

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8.9.29 CH2 Clear UART Errors (7CH)...................................................................................53
8.9.30 CH2 Clear Stats (7DH) ...............................................................................................53
9.0 APPENDIX............................................................................................................................54
9.1 Warranty...................................................................................................................................54
9.2 Principle of Operation...............................................................................................................54
9.3 Specifications...........................................................................................................................55
9.3.1 System Specifications.................................................................................................55
9.3.2 Mechanical Specifications...........................................................................................55
9.3.3 Electrical Specifications ..............................................................................................55
9.3.4 Environmental Specifications......................................................................................57
9.4 Approvals.................................................................................................................................57
9.5 Spare Parts and Accessories...................................................................................................57
9.5.1 Sensors.......................................................................................................................57
9.5.2 Sensor Housing...........................................................................................................58
9.5.3 Sensor Accessories ....................................................................................................58
9.5.4 Calibration Equipment.................................................................................................58
9.5.5 Intelligent Sensor (Ultima MOS-5 Intelligent Sensor) Replacement Parts .................59
9.5.6 Recommended Spare Parts for One Year..................................................................59
9.6 FM Approval.............................................................................................................................60

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Table of Figures
Figure 1: Ultima MOS-5 Intelligent Sensor Outline and Mounting Dimensions, in inches.....................................1
Figure 2: Spring Type Terminal Block Operation...................................................................................................2
Figure 3: Screw Type Terminal Block Operation....................................................................................................2
Figure 4: Ultima MOS-5 Intelligent Sensor.............................................................................................................7
Figure 5: Ultima MOS-5 Intelligent Sensor Outline and Mounting Dimensions, in inches...................................10
Figure 6: Ultima MOS-5 Intelligent Sensor Terminal Block Locations .................................................................11
Figure 7: Spring Type Terminal Block Operation.................................................................................................12
Figure 8: Screw Type Terminal Block Operation..................................................................................................13
Figure 9: Wire Strip Length...................................................................................................................................13
Figure 10: Relay Protection for DC and AC Loads...............................................................................................14
Figure 11: Relay Reset.........................................................................................................................................18
Figure 12: User Menu Structure...........................................................................................................................19
Figure 13: Gas Check...........................................................................................................................................23
Figure 14: Automatic Calibration Mode................................................................................................................24
Figure 15: Calibration in Progress Mode..............................................................................................................24
Figure 16: Calibration Complete Mode.................................................................................................................25
Figure 17: Ampoules.............................................................................................................................................26
Figure 18: Portable Purge Calibrator....................................................................................................................27

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Table of Tables
Table 1: TB2 Power and Signal Connections.......................................................................................................12
Table 2: Alarm Relay Connections.......................................................................................................................14
Table 3: Warn Relay Connections........................................................................................................................14
Table 4: Fault Relay Connections ........................................................................................................................14
Table 5: MSA Contact Information .......................................................................................................................32
Table 6: Data Format............................................................................................................................................33
Table 7: Exception Codes ....................................................................................................................................37
Table 8: Command Register Locations................................................................................................................40
Table 9: Com1 Baud Rate....................................................................................................................................45
Table 10: Com1 Data Format...............................................................................................................................45
Table 11: Com2 Baud Rate..................................................................................................................................45
Table 12: Com2 Data Format...............................................................................................................................46
Table 13: Sensor Scale ........................................................................................................................................46
Table 14: 24 VDC Cable Lengths.........................................................................................................................56
Table 15: Analog Output Cable Lengths ..............................................................................................................56
Table 16: Sensor Cable Lengths..........................................................................................................................56

1
Ultima MOS-5 Detector
Quick Start Guide
Mounting and Wiring
Tools Required
•“5mm” Allen head wrench to remove enclosure lid (included with gas detector).
•Flat-head screwdriver maximum 3/16 in (5 mm) width for terminal block (not included).
•Adjustable wrench for conduit or cable gland connections (not included).
The outline and mounting dimensions for the Ultima MOS-5 Intelligent Sensor (Figure 1) should
be used when making installation determinations.
Information on Class I Division 1 and Zone 1 wiring methods can be found in the NEC and
CEC.
WARNING: Acetic acid will cause damage to metal components, metal hardware, ceramic
IC’s, etc. If damage results from the use of a sealant that outgases acetic acid
(RTV silicone), the warranty will be void.
Figure 1: Ultima MOS-5 Intelligent Sensor Outline and Mounting Dimensions, in inches
Terminal Connections
The terminal blocks (TB) are located inside the housing and can be accessed by removing the
cover. A label inside of the housing cover provides a diagram of all the terminal connections.
It is recommended that a minimum three-wire shielded cable be used for making the power and
0-20mA Output connection on TB2 of the Ultima MOS-5 Intelligent Sensor. It is also
recommended that separate two-wire shielded twisted pair cables be used for making the
Modbus connections. The spring type terminal block accepts 14 AWG to 20 AWG and the

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screw type terminal block accepts 12 AWG to 18 AWG stranded or solid wire. Each wire should
be stripped before wiring the Ultima MOS-5 Intelligent Sensor. To connect wiring to the spring
type terminal block, insert a screwdriver into the orange tab and press down (Figure 2), opening
the terminal. Insert the wire into the terminal and release the orange tab, clamping the wire in
the terminal. Check the hold of the wire by gently tugging it to ensure it is locked in.
Figure 2: Spring Type Terminal Block Operation
To connect wiring to the screw type terminal block, loosen the top screw counter clock wise
(Figure 3). Insert the wire into the terminal and tighten the top screw clockwise.
Figure 3: Screw Type Terminal Block Operation
NOTE: Power must remain disconnected until all other wiring connections have been made.
The maximum distance between the Ultima MOS-5 Intelligent Sensor and the power supply is
2,000 feet or 610 meters (each cable run should be as short as possible). See Section 9.3.3 for
cable length specifications.
Connect +24 VDC to TB2, position 9. Connect the ground or common wire to TB2, position 8.
For making power and ground connections to display devices, see Figures 2 and 3.
To connect the analog signal, please refer to Section 3.5.4.