MSA Ultima Series User manual

GB-Ultima X Calibrator 29.10.2004 9:59 Uhr Seite 1

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Kernweg 20
NL-1627 LH Hoorn
P.O. Box 39
NL-1620 AA Hoorn
Phone +31 [229] 25 03 03
Telefax +31 [229] 21 13 40
E-Mail [email protected]
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Sterrenstraat 58/1
B-2500 Lier
Phone +32 [3] 491 91 50
Telefax +32 [3] 491 91 51
E-Mail [e-mail]
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MMSSAA[[BBrriittaaiinn]]LLiimmiitteedd
East Shawhead
Coatbridge ML5 4TD
Scotland
Phone +44 [12 36] 42 49 66
Telefax +44 [12 36] 44 08 81
E-Mail [email protected].uk
SSwweeddeenn
MMSSAANNOORRDDIICC
Kopparbergsgatan 29
SE-214 44 Malmö
Phone +46 [40] 699 07 70
Telefax +46 [40] 699 07 77
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Rörläggarvägen 8
SE-33153 Värnamo
Phone +46 [370] 699 35 50
Telefax +46 [370] 699 35 55
E-Mail [email protected]
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Thiemannstraße 1
D-12059 Berlin
Phone +49 [30] 68 86-25 99
Telefax +49 [30] 68 86-15 17
E-Mail [e-mail]
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Francia út. 10
H-1143 Budapest
Phone +36 [1] 251 34 88
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ul. Wschodnia 5A
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Office 14
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Phone +7 [095] 239 15 72
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Thiemannstraße 1
D-12059 Berlin
Phone +49 [30] 68 86-55 5
Telefax +49 [30] 68 86-15 17
E-Mail [e-mail]
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Via Po 13/17
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GB-Ultima X Calibrator 29.10.2004 9:59 Uhr Seite 2

Ultima/Ultima® X Series
Controller and Calibrator
Instruction Manual
Rev. 3 October 2004
P/N 10046691
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GB-Ultima X Calibrator 29.10.2004 9:59 Uhr Seite 4

▲
!
Notice !
Like any piece of complex equipment, this product
will do the job it is designed to do, only if it is
used and serviced in accordance with the man-
ufacturer’s instructions. This manual must be
carefully read by all individuals who have or will
have the responsibility for using or servicing the
product.
The warranties made by MSA AUER GmbH 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 your employees by following them. The
product has to be controlled and serviced regu-
larly by competent and authorized personnel.
The results of the inspections and services have
to be recorded.
Before choosing and using this product, it is
required to assess whether this product is suit-
able for the application intended. Choice and
use are beyond the control of MSA AUER GmbH.
Therefore, the liability of MSA AUER GmbH
covers only the consistent quality of this product.
Instruments and components which have been
tested and certified shall only be maintained and
used in accordance with the relevant instructions
in the certificates.
Modifications on instruments and components
and the use of defective or incomplete instru-
ments or components are not permissible.
Apart from MSA AUER GmbH, authorized work-
shops can carry out maintenance work. These
workshops are responsible to obtain the latest
technical information on the instruments and
components from MSA AUER GmbH. The above
does not alter statements regarding the
warranties and conditions of sale and deliveries
of MSA AUER GmbH.
3
Instruction Manual
WARNING
THIS MANUAL MUST BE CAREFULLY READ
BY ALL INDIVIDUALS WHO HAVE OR WILL
HAVE THE RESPONSIBILITY FOR USING OR
SERVICING THESE PRODUCTS. Like any piece
of complex equipment, the units will perform as
designed only if installed, used and serviced in
accordance with the manufacturer’s instructions.
OTHERWISE THEY COULD FAIL TO PERFORM
AS DESIGNED AND PERSONS WHO RELY ON
THESE PRODUCTS FOR THEIR SAFETY
COULD SUSTAIN SEVERE PERSONAL INJURY
OR DEATH.
The warranties made by Mine Safety Appliances
Company with respect to these products are
voided if the products are 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
repairs.
IIn the U.S., to contact your nearest stocking
location, dial toll-free 1-800-MSA-INST. To contact
MSA International, dial 1-412-967-3354.
(c)MINE SAFETY APPLIANCES COMPANY 2002
– All Rights Reserved
Manufactured by
MSA INSTRUMENT DIVISION
P.O. Box 427, Pittsburgh, Pennsylvania 15230
GB-Ultima X Calibrator 29.10.2004 9:59 Uhr Seite 5

Table of Contents
Section 1
General Information 6
The ULTIMA/ULTIMA X Calibrator 6
Three Function Operation 6
Figure 1-1.Ultima Calibrator 6
To Operate: 6
The ULTIMA/ULTIMA X Controller 6
Figure 1-2. 6
Pointing the Calibrator at the ULTIMA
Gas Monitor Display
Figure 1 -3. 7
ULTIMA/ULTIMA X Controller
Setting up the Controller 7
Using the ID CODE Feature 7
To Enable or Change the Password ID 7
To Disable the Password ID 7
Turning the Controller ON 7
Turning the Controller OFF 7
Setting the Controller for an ULTIMA 8
or ULTIMA X Series Instrument
Setting the Internal TIME of the Controller 8
Setting the Internal DATE of the Controller 8
When Sending a Command to the 8
ULTIMA/ULTIMA X Series Gas Monitor
Note on Resetting latched Alarms 8
Section 2
Calibration 9
Equipment Required 9
WARNING 9
Span Gas Values 9
WARNING 9
Table 2-1. 10
Factory-set Span Values
Figure 2-1. 11
Calibration Kit 40 Contents
Figure 2-2. 11
Calibration Kit 41 Contents
Gas Sensor 11
Table 2-2. 12
Calibration Guide for Catalytic Type 1S
Combustible Gas Sensor
ULTIMA/ULTIMA X Series Gas Monitor 14
Calibration
WARNING 14
INITIAL Calibration 14
Regular Calibration 15
Zeroing 15
Spanning 16
Figure 2-3. 16
ULTIMA Unit Apply SPAN Gas Flag
Figure 2-4. 16
ULTIMA X Unit Apply SPAN Gas Flag
Figure 2-5. 17
Span Set-up (ULTIMA unit shown)
Figure 2-6. 17
ULTIMA X Series Unit Calibration
End Display
Figure 2-7. 17
Span Gas Connection (ULTIMA unit shown)
OXYGEN Calibration 18
25% Oxygen ULTIMA/ULTIMA X Series 18
Gas Monitor
XIR Calibration 18
Section 3
Controller - Detailed Operation 19
Viewing the Ultima Gas Monitor 19
Display Modes
Table 3-1. 19
(see “Procedures”) The Controller Can
Change the Ultima Gas Monitor Display
to Show:
To View the Status of the Ultima Gas Monitor 20
Procedures 20
Procedure 1. 20
Setting the Average Time Interval
To Change the Average Time Interval 20
Procedure 2. 21
Setting the Span Value
To Change the Calibration Span Gas 21
Value of the ULTIMA Sensor
To Change the Calibration Span Gas 21
Value of the ULTIMA X Series Sensor
Procedure 3. 21
Setting the Range on an ULTIMA X Series
Sensor
Procedure 4 22
Setting the Gas Table for the ULTIMA XIR
Sensor
Procedure 5. 22
Setting the Three ULTIMA Gas Monitor
Alarm Setpoint Values
Setting the Three ULTIMA X Series Gas 23
Monitor Alarm Setpoint Values
To set the three levels of alarm: 23
Enabling/Disabling and Setting the 23
Mode of the Three ULTIMA Alarm Setpoints
Enabling/Disabling and setting the 23
Mode of the Three Ultima X Series
Alarm Setpoints
4
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Procedure 6. 24
Setting the Current Time
To Update the ULTIMA Gas Monitor 24
internal clock:
Procedure 7.
Setting the Current Date 24
To Update the ULTIMA Gas Monitor 25
internal date
Procedure 8. 25
Enabling/Disabling ULTIMA Gas Monitor
Calibration Output Signal
Procedure 9. 25
Setting the Number of Days
Between ULTIMA Gas Monitor
Auto-calibration Periods
Setting the Time that ULTIMA Gas 26
Monitor Auto-calibration is to begin
Procedure 10. 26
Setting the Date of the Next Scheduled
ULTIMA Gas Monitor Calibration .
Procedure 11. 26
Changing the MUX Address
Procedure 12. 26
Viewing the Previous Successful
Calibration Date ...
Procedure 13. 26
Calibrating/Checking the 4-20mA
ULTIMA X Series Outputs
Procedure 14. 27
Resetting the ULTIMA X Series Monitors
Procedure 15. 27
Setting the Alert Option on an
ULTIMA X Series Sensor
Table 3-2. Alert Operation Settings 27
Procedure 16. 28
Setting the Sensor Swap Delay on an
ULTIMA X Sensor
Programming the Controller 28
Removing Existing Programs 28
Adding a New Program 28
Linking or Combining Programs 28
To Link Programs 28
To Use Programs 1 through 8 29
To use Program #9 29
To use Program #0 29
Section 4
Maintenance 29
WARNING 29
Batteries 29
Determining a Low Battery Condition 29
on the ULTIMA Controller
To Determine if Battery Replacement is 29
Necessary
Replacing the Batteries 29
To Install New Batteries in the 30
ULTIMA Controller
Determining a Low Battery Condition 30
on the ULTIMA Calibrator
To Install New Batteries in the 30
ULTIMA Calibrator
Service 30
WARNING 30
Troubleshooting Guidelines 30
Marking , Certificates and Approvals 31
according to the Directive 94/9/EC ( ATEX )
5
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Section 1
General Information
This manual describes the Operation and use
of the ULTIMA Controller and ULTIMA Calibrator
for the ULTIMA/ULTIMA X Series Gas Monitors.
It is strongly recommended that this entire
manual be read before using the Controller or the
^^Calibrator.
The Controller and Calibrator use an Infrared (IR)
LED to transmit to an IR receiver in the
ULTIMA/ULTIMA X Series Gas Monitor.
The ULTIMA/ULTIMA X Calibrator (FIGURE 1-1):
●Is a hand-held, self-contained unit powered
by two internal AAA batteries
●Allows one person, non-intrusive calibration
of an ULTIMA/ULTIMA X Series Gas Monitor,
enabling the Monitor to be calibrated at
the unit without opening the enclosure
●Is an intrinsically safe product for use in
hazardous areas (see Marking,Certificates
and Approvals according to the Directive
94/9/EC).
●Can select the multiplex address of an
ULTIMA/ULTIMA X Series Gas Monitor set
up in the multiplex mode (if your monitor is
so equipped)
●Requires no adjustments
●Features simple, three-button Operation
●Provides Auto power ON/OFF.
Three Function Operation
The Ultima Calibrator is equipped with three
buttons for the following functions:
1. ZERO Button:
●Performs a zero function on the
ULTIMA/ULTIMA X Series Gas Monitor;
periodically, the monitor may require
only a zero adjustment.
2. CALIBRATE Button:
●Performs a zero and span calibration
function on the ULTIMA/ULTIMA X
Series Monitor; During a complete
calibration, the ULTIMA Gas Monitor
requires both a zero and span check
gas.
3. ADDRESS Button:
●Displays or changes the multiplex
address on the ULTIMA/ULTIMA X Series
Monitor, if so equipped.
To Operate:
●All ULTIMA Calibrator operations are
performed by simply pointing the Calibrator
at the ULTIMA/ULTIMA X Series Gas Monitor
display from a distance of no greater than six
inches (FIGURE1-2).
Figure 1-2.
Pointing the Calibrator at the ULTIMA Gas Monitor
Display
Communication to the ULTIMA/ULTIMA X Series
Gas Monitor is made via a one way, digitally
encoded lR link to ensure tamper-proof and
reliable nonintrusive communication.
6
GB-Ultima X Calibrator 29.10.2004 9:59 Uhr Seite 8

The ULTIMA/ULTIMA X Controller
(FIGURE1-3):
Figure 1-3.
Ultima/Ultima X Controller
●Allows non intrusive calibration of an
ULTIMA/ULTIMA X Series Gas Monitor,
enabling the Monitor to be calibrated at
the unit without opening the enclosure
●Is a hand-held, self-contained unit powered
by two internal AA batteries
●Is an intrinsically safe product for use in
hazardous areas (see Marking, Certificates
and Approvals according to the Directive
94/9/EC).
●Is approved with a covering leather
●Can select the following on an ULTIMA/
ULTIMA X Gas Monitor:
●Set Monitor time and date
●Set the average interval
●Set/display span gas value
●Set/display alarms
●Display minimum, maximum, and average
gas readings
●Enable calibration Output Signal
●Configure auto-calibration feature
●Display previous calibration date
●Set/display address
●Mimic Calibrator
●Set/Display Range (ULTIMA X Series
units only)
Setting up the Controller
Using the ID CODE Feature
Controller Operation can be password-protected
to prevent Operation by unauthorised personnel.
All Ultima Controller units are shipped from the
factory with Password lD disabled.
To Enable or Change the Password ID
1. With the unit OFF, press and hold the ENTER
button for approximately five seconds, until
the display prompts: ID KEY ####.
2. Use the NUMBER buttons:
●To CHANGE password ID by entering the
old ID number (go to Step 3)
●To ENABLE a password ID by entering
9999.
3. Press the ENTER button.
●The display prompts: NEW KEY ####.
4. Enter the desired four-digit ID and press the
ENTER button.
●The unit enters the READY mode and
saves the l D password required for
future Operation.
To Disable the Password ID
1. With the unit OFF, press and hold the ENTER
button until the display prompts:
ID KEY ####.
2. Using the NUMBER buttons, enter the old
ID number.
3. After entering the four-digit number, press
the ENTER button.
●The display prompts: NEW KEY ####.
4. Enter 9999 and press the ENTER button.
●The unit enters the READY mode and
disables the password ID function for
future Operation.
NOTE:
If the ID password is set and forgotten, contact
an MSA service representative.
Tur ning the Controller ON
Press the ENTER button.
●Unit performs a self-test and displays the
firmware version for several seconds
●If unit displays the ULTIMA READY or
ULTIMA X READY prompt, it is ready for use
●If unit displays the ID CODE prompt, enter
the user-selected password ID (see “Using
the ID CODE Feature”).
Tur ning the Controller OFF
●The unit turns OFF automatically approxi-
mately 100 seconds after the last button is
pressed
●To manually turn OFF the unit, press and
hold the CLEAR button for five seconds.
NOTE:
A dual beep tone sounds when CLEAR button is
pressed.
7
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Setting the Controller for an ULTIMA or
ULTIMA X Series Instrument
The ULTIMA Controller features the capability to
transmit to both the ULTIMA and ULTIMA X
Series instruments. To select the target instrument:
1. Turn unit ON to place into the READY mode.
●Display prompts: ULTIMA READY or
ULTIMAX READY.
(see “Turning the Controller ON.”)
2. Press the DISPLAY button once.
●Display prompts: 0=ULTMA 1=ULTMX.
3. Enter “0” to set the Controller for an ULTIMA
instrument or “1” to set the Controller for an
ULTIMA X Series instrument.
a. If your entry is valid, the Controller will
display “ULTIMA READY” or “ULTIMAX
READY”.
b. If your entry is invalid, it will not be
accepted. Start this procedure again to
change the Controller type.
Setting the Internal TIME of the Controller
The ULTIMA/ULTIMA X Controller features an
internal real time clock for time/date stamping.
To set the real time clock:
NOTE:
Momentarily pressing the TIME button displays
the current hours and minutes. Press the CLEAR
button to return to the READY mode.
1. Place unit in the READY mode
●Display prompts: “ULTIMA READY” or
“ULTIMAX READY”. (see “Turning the
Controller ON.”)
2. Press and hold TIME button until the HH:MM
prompt appears.
3. Using the NUMBER buttons, enter the current
time in 24-hour format (e.g.: 4:00 P.M.
= 16:00). (Leading zeros are required.)
a. If your entry is valid, press ENTER button
to save this time.
b. If your entry is invalid, it will not be
accepted; re-enter the correct time or
press the CLEAR button to cancel and
Start over.
●The DEL button allows for correction
during entry.
Setting the Internal DATE of the Controller
NOTE:
Momentarily pressing the DATE button displays
the current date.
1. Place unit in the READY mode.
●Display prompts: “ULTIMA READY” or
“ULTIMAX READY”.
2. Press and hold the DATE button until the
MM-DD-YYYY prompt appears. (Leading
zeros are required.)
3. Enter the current date using the NUMBER
buttons.
a. If your entry is valid, press ENTER button
to save that date.
b. If your entry is invalid, it will not be
accepted; re-enter date or press the
CLEAR button to cancel and Start this
procedure again.
●The DEL button allows for correction
during entry.
When Sending a Command to the
ULTIMA/ULTIMA X Series Gas Monitor
1. The Controller must be READY prior to any
key press.
2. To change any function on the ULTIMA/
ULTIMA X Series Gas Monitor, point the top
of the Controller directly at the clear
face of the sensor (FIGURE 1-2) and press
the desired sequence of Controller buttons.
(Controller must be pointed at sensor when
final button of sequence is pressed.)
●The top surface of the Controller must be
within six inches of the sensor face to
enable reception
●Each button pressed is acknowledged
by a short beep
●The CLEAR button is acknowledged by a
double beep
●When invalid responses are entered, the
Controller resets to the READY mode or
re-prompts user for a correct entry.
Note on Resetting latched Alarms
When an ULTIMA/ULTIMA X Gas Monitor has an
active latched alarm (indicated by a flashing
alarm display):
●An infrared (IR) remote device (such as the
ULTIMA Calibrator or ULTIMA Controller)
may be used to reset this alarm.
●If an ULTIMA/ULTIMA X Series Gas Monitor
has an active latched alarm, the next lR
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 use.
8
GB-Ultima X Calibrator 29.10.2004 9:59 Uhr Seite 10

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Section 2
Calibration
The ULTIMA/ULTIMA X Series Gas Monitor
provides non-intrusive Calibration through the
use of the ULTIMA Controller/Calibrator.
When calibrating any ULTIMA/ULTIMA X Series
Gas Monitor which has any accessory attached
to it, refer to the accessory manual for complete
Calibration instructions. Some accessories
for the ULTIMA/ULTIMA X Series Gas Monitor
include:
●ULTIMA Sampling Module
●ULTIMA Auto-Cal Module.
While factory Calibration is Standard practice for
the ULTIMA/ULTIMA X Series Gas Monitors, it is
recommended to perform an INITIAL Calibration
when first placing the unit into Operation. Refer
to the “Initial Calibration” portion of this Chapter.
It is good practice to read the appropriate
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 ease of
unit Calibration.
Equipment Required
Two Calibration kits (numbered 40 and 41; see
FIGURES 2-1 and 2-2) are available from MSA
for diffusion ULTIMA/ULTIMA X Series Gas
Monitors. Kit 40 and 41 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 Sampling
Modules or an ULTIMA/ULTIMA X Series unit
equipped with a flow cap. For flow or sample
module Systems, refer to the ULTIMA Aspirated
Sampling Module Manual (P/N 710200) or to the
ULTIMA DC Pump Sampling Module Manual
(P/N 710201).
NOTE:
The Calibration procedure for the sample draw
ULTIMA X 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.
9
The check or calibration gases can also be
carried in the case. See TABLE 2-1 for the appro-
priate zero and span gas cylinders for your
ULTIMA/ULTIMA X Series Gas Monitor.
TABLE 2-1 shows the recommended calibration
kit for ULTIMA and ULTIMA X Series Gas
Monitors. Cal Kit 41 uses 0.25 LPM regulator
and a rubber boot to contain the calibration gas.
Cal Kit 40 uses a 1.5 LPM regulator and no
rubber calibration boot. If Cal Kit 41 is recom-
mended and the application is such that the
rubber cal boot 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 minimised 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.
WARNING
For zero calibration you have to use always
zero gas when zeroing the ULTIMA X Monitor;
otherwise, improper calibration could occur.
Span Gas Values
The ULTIMA/ULTIMA X Monitor is factory-
shipped with a preset span gas value (TABLE 2-1).
This span gas value can be changed via the
ULTIMA Controller; otherwise, the span gas must
correspond to preset concentrations. See
Section 3 to change the span gas value.
WARNING
The span gas value of ULTIMA Gas Monitor
combustible models are pre-set to one of the
broad categories shown in TABLE 2-1. Typical
gases or vapours are listed under each cate-
gory given in TABLE 2-2.
Always calibrate for the least sensitive gas
or vapour (higher number category) expected
to be measured (TABLE 2-2); otherwise,
instrument readings may be incorrect.
GB-Ultima X Calibrator 29.10.2004 9:59 Uhr Seite 11

10
Table 2-1. Factory-set Span Values
GAS TYPE RANGE SPAN GAS MSA RP CALI-
PRESET VALUES CYLINDER P/N BRATION KIT
CARBON MONOXIDE 0-100 PPM 60 PPM 710882 40
0-500 PPM 300 PPM 1 0027938
SULFUR DIOXIDE 0-25 PPM 10 PPM 1 0028070
HYDROGEN SULFIDE 0-10 PPM 5 PPM 710414
0-50 PPM 40 PPM 1 0028062
0-100 PPM
NITRIC OXIDE 0-100 PPM 50 PPM 1 0028074
NITROGEN DIOXIDE 0-10 PPM 5 PPM 710332 41
CHLORINE 0-5 PPM 2 PPM 710331
HYDROGEN CYANIDE 0-50 PPM 10 PPM 1 0028072
HYDROGEN CHLORIDE(5) 0-50 PPM 40 PPM 1 0028060
CHLORINE DIOXIDE(4) 0-3 PPM 1 PPM 710331
OXYGEN 0-5% 5% 493580 40
0-25% 20.8% 10028028
(2)
NATURAL GAS(3) 0-100% LEL 25% LEL(1) 1 0028034
PETROLEUM VAPORS(3) 0-100% LEL 40% LEL(1)
(GASOLINE)
GENERAL SOLVENTS(3) 0-100% LEL 55% LEL(1)
NON-METHANE IR 0-100% 29% LEL(1)
METHANE IR 0-100% LEL 50% LEL(6) 1 0028032
PHOSPHINE 2.0 PPM 0.5 PPM 710533 41
ARSINE 2.0 PPM 1.0 PPM
GERMANE 3.0 PPM 2.5 PPM
SILANE 25 PPM 5 PPM 10014897
DIBORANE 50 PPM 15 PPM
FLUORINE 5.0 PPM 4.0 PPM 710331
BROMINE 5.0 PPM 2.5 PPM
AMMONIA 0-50 PPM 25 PPM 1 0028076 40
HYDROGEN 0-1000 PPM 500 PPM 1 0022386
ETO (7) 0-10 PPM 4.0 PPM 1 0028070
CARBON DIOXIDE IR 0-2% 1 .5% 807386
NOTES:
1 CALIBRATED WITH PROFANE (.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 CL02 IS CALIBRATED WITH CL2 OR USE CLO2 CALIBRATOR KIT (P/N 710420)
5 HCL IS CALIBRATED WITH H2S
6 METHANE IR IS CALIBRATED WITH 50% LEL METHANE.
7 ETO IS CALIBRATED WITH SO2.
The calculation between the LEL and the Vol% for the calibration gas value has to be done according the
local regulation.
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1/4” -ID 3/16” -ID
Item 1 – Tubing (P/N 711112)
– 3/16” ID side connects to item 3
– 1/4” ID side connections to sensor
Item 2 – Zero Cap
(P/N 710535)
Item 3 – 1,5 LPM Flow
Controller (P/N. 478358)
Figure 2-1.
Calibration Kit 40 Contents (Your Kit may also include one or two gas cylinders)
1/4” -ID 3/16” -ID
Item 1 – Tubing (P/N 711112)
– 3/16” ID side connects to item 3
– 1/4” ID side connections to sensor
Item 2 – 0,25 LPM Flow Controller
(P/N 478359)
Item 3
– Calibration Cap
(P/N 710411
Item 4
– Zero Cap
(P/N 813774)
Item 5
– Calibration Cap
(P/N 10020030)
Item 6
– Zero Cap
(P/N 710535)
Figure 2-2.
Calibration Kit Contents (Your Kit may also include one or two gas cylinder)
11
The Span gas values can be set between
For LEL = 1% to 100%
For oxygen = 0,1 Vol% to 25 Vol%
The upper of the measuring range for LEL and
oxygen can be set between
For LEL = 5% to 100%
For oxygen = 0.5 Vol% to 25 Vol%
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Table 2-2 is not valid for ATEX Applications
Table 2-2.
Calibration Guide for Combustible Gas Sensor
CATEGORY 31 : NATURAL GAS
To detect the following gases, recalibrate with 0.6% Propane and set the span gas value accordingly
Acetaldehyde 23 Hydrogen 16
Acetylene 24 MAPP Gas 20
Butadiene. 1. 3 25 Methane 20
Carbon Monoxide 20 Methanol 20
Ethane 24 Methylene Chloride 24
Ethylene 25 Monomethyl Amine 22
Ethylene Dichloride 22 Trigonox B 22
CATEGORY 32: PETROLEUM VAPOURS
To detect the following gases, set span point at 40% LEL with 0.6% Propane applied to sensor
1.1.1 -Trichloroethane 32 Ethylene Oxide 36
Acetic Acid 28 Freon 152A 28
Acetone 37 Gasoline 35
Acrolein 28 Hexane 40
Acrylonitrile 26 Isoprene 33
Allyl Chloride 30 Methyl Acetate 34
Benzene 37 Methyl Chloride 32
Butane (n) 36 Methyl Propane (2) 29
Butane (iso) 32 Methyl t-Butyl Ether 35
Butanol (iso) 38 Pentane (n) 36
Butene-1 34 Pentane (iso) 36
Butene-2 37 Pentene 35
Butyl Acetate (n) 28 Propane 29
Butylene 33 Propanol (n) 36
Butyraldehyde 30 Propanol (iso) 37
Chlorobenzene 38 Propylene 33
Cyclohexane 37 Propylene Oxide 33
Dimethoxyethane 26 Tetrahydrofuran 30
Dioxane. 1. 4 39 Toluene 39
Epichlorhydrin 33 Trichloroethylene 35
Ethanol 30 Triethylamine 38
Ether. Diethyl 37 Vinyl Acetate 34
Ether. Dimethyl 30 Vinyl Chloride 32
12
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CATEGORY 33: FOR CATALYTIC TYPE 1S GENERAL SOLVENTS
To detect the following gases, recalibrate with 0.6% Propane and set the span gas value accordingly
Amyl alcohol 43 JP-4 41
Butanol (n) 48 Methyl Cellosolve 49
Butyl Acrylate 46 Methyl Ethyl Ketone 52
Cellosolve 42 Methyl Isobutyl Ketone 53
Di isopropylamine 42 Methyl Methacrylate 40
Diethylamine 41 Naphtha. VMSP 53
Ethyl Acetate 43 Getane (iso) 52
Ethyl Acrylate 52 Propyl Acetate 45
Ethyl Benzene 41 Styrene 42
Heptane 42 Xylene 50
Hexene 42
Table 2-2.
Calibration Guide for Combustible Gas Sensor
CATEGORY 34: ULTIMA IR METHANE
To detect the following gases, recalibrate with 2.5% methane and set the span gas
value accordingly:
Acetone 86 Isoproponal 25
Butadiene, 1, 3 80 MEK 53
Cyclohexane 14 Methane 50
Ethanol 17 Methanol 14
Ethyl Acetate 34 Methyl Formate 13
Ethylene 95 Propylene 39
Heptane 14 Toluene 64
Hexane 14 Xylenes 53
IsoButanol 20
CATEGORY 35: ULTIMA IR NON-METHANE
To detect the following gases, recalibrate with 0.6% propane and set the span gas
value accordingly:
Butane 31 IsoButane 33
Butyl Acetate 48 IsoButanol 47
Cyclohexane 37 IsoPropanol 52
Cyclopentane 32 Methanol 27
Dimethyl Ether 25 Methyl Formate 35
Ethane 30 Pentane 31
Ethanol 36 Propane 29
Ethylene Oxide 72 Propyl Acetate 51
Heptane 36 Propyl Alcohol 31
Hexane 37 Propylene Oxide 26
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CATEGORY 38: ULTIMA XIR METHANE
To detect the following gases, recalibrate with 25% methane and set the span gas
value accordingly:
Methane 50
CATEGORY 39: ULTIMA XIR NON-METHANE
To detect the following gases, recalibrate with the stated % propane and set the
span gas value accordingly:
Butane, 0.6% propane 28 Hexane 0.6% propane 41
Cyclopentane, 0.6% propane 30 Pentane 0.6% propane 33
Ethane, 0.6% propane 25 Propane 0.6% propane 29
Ethylene, 0.1% propane 28
▲
!
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 Chapter 2,
“Oxygen Calibration.”
●If this is an XIR sensor, see Section 2, “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
CLO2ULTIMA/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.
●Due to the reactivity of HCL with flow System
components, gas can be used as a calibration
Simulant. If using the MSA calibration
System and gas cylinder (P/N 467898, 10 ppm
in Nitrogen) the span value should be set to
40 ppm of HCL (the default span value
of HCL).
INITIAL Calibration
When a new sensor is placed in the ULTIMA Gas
Monitor, an INITIAL Calibration must be per-
formed. When a new sensor is placed in the
ULTIMA X Gas Monitor, an INITIAL Calibration is
also needed. 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.
14
Example:
If measuring gases or vapours that appear in
TABLE 2-2, Category 2 and Category 3, you
should calibrate to the Category 3 span value
(55% LEL) with 0.6% Propane by volume
applied.
If the gas or vapour you are measuring does not
appear in the TABLE 2-2 categories, consult
MSA for the proper setting. If you wish to
calibrate to the specific LEL of the gas or vapour
being measured, the expected span gas value of
the ULTIMA/ULTIMA X Series Gas Monitor
can be changed by the ULTIMA Controller.
ULTIMA/ULTIMA X Series Gas Monitor
Calibration
WARNING
To ensure a fully functional sensor, perform
Calibration checks and adjustments at initial
start-up and at regular intervals.
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 calibra-
tion records prove sensor stability. The calibration
frequency can then be reduced to the schedule
set by the safety officer or plant manager.
In some cases, it may be necessary to perform
only a zero function of the Gas Monitor in lieu of
a full zero and span procedure. Check with your
safety officer or safety engineer to determine if
only a zero function is necessary.
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Additionally, INITIAL Calibration should only be
used when a regular calibration will not clear a
fault condition due to use of incorrect cal gas or
other similar Situation.
Initial calibration is accomplished by:
●pressing the ZERO and CALIBRATE buttons
simultaneously on the ULTIMA Calibrator
●pressing and holding the SPAN button on the
ULTIMA Controller
●The Controller display shows
“Do Init Cal 1=y”
●Press 1 while pointing the Controller at
the ULTIMA/ULTIMA X Series display.
●The ULTIMA display should show
“SET APPLY ZERO GAS”
●The ULTIMA X Series display should show
“APPLY ZERO GAS”
●The remainder of the procedure is now the
same as that for a regular calibration.
●The presence of the words “SET” (on ULTIMA
units only) and “ICAL” (on both ULTIMA and
ULTIMA X Series units) on the display distin-
guish INITIAL Calibration from a regular
calibration. If the word “ICAL” does not appear,
the user may abort the calibration by press-
ing any button on the Calibrator while aiming
at the unit; then, retry the above procedure.
NOTE:
The calibration process can be aborted at any
time during the 30-second Countdown simply by
pressing the ZERO, CAL or ADDRESS button on
the Controller/Calibrator while aiming at the unit.
●The display leads the user through the zero
and span routines as in a regular calibration.
NOTE:
This procedure should be initiated only when
a new sensor element is installed. Otherwise, the
sensor end-of-life indication may not be accurate.
Regular Calibration
A regular calibration includes a “zero” and “span”
as described in the following procedures. If the
user chooses to only perform a “zero”, they may
do so by pressing the ZERO button instead of
the CALIBRATE or CAL button as described in
step 3.
●For oxygen units, skip to Step 3.
Zeroing
1. 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 Calibration Kit Tube
Assembly.
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, (or Cal Kit 40 with
the ULTIMA XIR), locate the Cal Cap
with a 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 (see FIGURE 2-7).
Note:
The calibration cap (P/N 10041533) for the
ULTIMA XIR is shipped with the product and is
not contained in the calibration kit.
f. Turn ON the gas flow by turning the knob
on the flow Controller.
2. Point the ULTIMA Controller/Calibrator at the
ULTIMA/ULTIMA X Monitor display and
press the Controller/Calibrator CAL/
CALIBRATE button.
The display shows:
●A Countdown from 30 to 0 seconds
●APPLY ZERO GAS.
NOTE:
The zero or calibration process can be aborted
at any time during the 30-second Countdown
interval; simply press the ZERO, CAL or
ADDRESS button on the Controller/Calibrator
while aiming it at the unit.
NOTE:
The 30-second Countdown interval is omitted
for oxygen units. It is electronically zeroed.
15
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Figure 2-3
ULTIMA Unit Apply SPAN Gas Flag
●The span process can be aborted at any
time during the Countdown by simply
pressing the ZERO, CAL or ADDRESS
button on the Controller/Calibrator while
aiming it at the unit.
Figure 2-4
5. Locate the span gas cylinder and the
Calibration Kit Flow Controller.
6. Screw the Flow Controller onto the top of
the span gas cylinder.
7. Locate the Calibration Kit Tube Assembly.
8. 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.
9. When using:
a. Cal Kit 40, connect the other end of the
tubing over the SensorGard inlet
(FIGURE 2-5).
b. Cal Kit 41(or Cal Kit 40 with the
ULTIMA XIR), 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 (see FIGURE 2-7).
10. 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 30-second count
down period.
3. After the 30 second Countdown:
●The display alternates between “CAL”
and a value (example: 0 PPM). This value
is the actual reading of the gas concen-
tration the sensor is detecting. The
engineering units (PPM, % or %LEL) are
predetermined by the type of sensor
installed and are not changeable.
●Once the gas value is stable, the alter-
nating display stops. If the calibration is
successful, the display will show END.
1) Turn OFF the gas flow by turning the flow
Controller knob.
2) Remove the tubing from the Flow Controller.
●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 a CAL FAULT flag appears on the unit,
this indicates:
●An unsuccessful attempt to zero or
calibrate the ULTIMA/ULTIMA X Series
Gas Monitor
●The ULTIMA/ULTIMA X Series Gas
Monitor is operating with the calibration
parameters defined before the
calibration was attempted.
●See Troubleshooting Guidelines found in
the ULTIMA manual (P/N 10046690).
To extinguish the CAL FAULT flag, a complete
successful calibration procedure must be
performed.
The ULTIMA/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 cali-
bration 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
4. During a regular calibration, the ULTIMA/
ULTIMA X Series Gas Monitor automatically
begins the span Countdown after a successful
zeroing of the unit. The span Countdown is
30 seconds (FIGURES 2-3 and 2-4).
16
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Figure 2-5
Span Set-up (ULTIMA unit shown)
●If CAL FAULT displays on the ULTIMA/
ULTIMA X Series Gas Monitor before the
user is able to apply the gas, a stable 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.
11. After the 30 second Countdown:
●The display alternates between “CAL”
and a value. (for example: 60 PPM for 0
to 100 ppm carbon monoxide). This
value is the actual reading of the gas
concentration the sensor is detecting.
The engineering units (PPM, % or %LEL)
are predetermined by the type of sensor
installed and are not changeable.
●Once the gas value is stable, the alter-
nating display stops. If the calibration is
successful, the display will show
END for approximately two seconds.
(FIGURE 2-6).
Figure 2-6
ULTIMA X Series Unit Calibration End Display
●No user adjustments are necessary.
●The display will show the span gas value
while the span gas is flowing to the
unit. (For example, it may read 60 PPM
or 25 % or 60 % LEL).
12. Turn OFF the gas flow by turning the knob on
the flow Controller.
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.
Figure 2-7.
Span Gas Connection (Ultima unit shown)
●When the span gas is removed from the
sensor, the sensor reading may take
several minutes to return to zero; this is
normal sensor Operation.
●If a CAL FAULT flag appears on the unit, this
indicates:
●An unsuccessful attempt to calibrate the
ULTIMA/ULTIMA X Series Gas Monitor
●The ULTIMA/ULTIMA X Series Gas Monitor
is operating with the calibration param-
eters defined before the calibration was
attempted.
To extinguish the CAL FAULT flag, a complete
calibration procedure must be performed.
SPAN CYLINDER
SENSORGARD
SPAN GAS
CYLINDER
CALIBRATION CAP
ROUTE TUBING FROM
CYLINDER TO GAS
SENSOR VIA SPLITS
17
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▲
!
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. 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 typ-
ically sufficient to restore its span performance.
A zero adjustment is performed by pressing the
ZERO button on the Calibrator or Controller and
following 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 sensor Guard (packaged with the instrument)
and perform the following procedure.
WARNING
The Calibration Cap must be removed from
the XIR sensor guard after completing the
Zeroing and/or Spanning procedure;
otherwise, the sensor cannot perform properly.
The ULTIMA/ULTIMA X Series Gas Monitor
allows automatic zero and span adjustments
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.
13. 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.
OXYGEN Calibration
NOTE:
If this is the first calibration after the sensor ele-
ment 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 oxy-
gen 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 repro-
ducibility 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 ade-
quate to simply allow the Countdown to occur
without applying gas.
NOTE:
If the sensor is located in an area of normally Iow
or enriched oxygen, then a 20.8% oxygen sample
must be applied when the display prompts:
“APPLY SPAN GAS”.
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