MSA ULTIMA X5000 User manual


Operating Manual
ULTIMA® X5000
Gas Monitor
 
OrderNo.:10177361/08
PrintSpec:10000005389(EO)
CR:800000055071
MSAsafety.com

© MSA 2020, 2022. All rights reserved
WARNING!
Readthismanualcarefullybeforeusingormaintainingthedevice.Thedevicewillperformasdesignedonlyifitisusedand
maintainedinaccordancewiththemanufacturer'sinstructions.Otherwise,itcouldfailtoperformasdesigned,andpersons
whorelyonthisdevicecouldsustainseriousinjuryordeath.
ThewarrantiesmadebyMSAwithrespecttotheproductarevoidediftheproductisnotinstalledandusedinaccordance
withtheinstructionsinthismanual.Pleaseprotectyourselfandyouremployeesbyfollowingtheinstructions.
PleasereadandobservetheWARNINGSandCAUTIONSinside.Foradditionalinformationrelativetouseorrepair,call
1-800-MSA-2222duringregularworkinghours.
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.
TheDeclarationofConformitycanbefoundunderthefollowinglink:https://MSAsafety.com/DoC.
MSAisaregisteredtrademarkofMSATechnology,LLCintheUS,EuropeandotherCountries.Forallothertrademarks
visithttps://us.msasafety.com/Trademarks.
ThisproductincorporatesBluetooth®wirelesstechnology.TheBluetoothwordmarkandlogosareregisteredtrademarks
ownedbyBluetoothSIG,Inc.,andanyuseofsuchmarksbyMSAisunderlicense.Othertrademarksandtradenamesare
thoseoftheirrespectiveowners.
Thisdevicecomplieswithpart15oftheFCCRules.Operationissubjecttothefollowingtwoconditions:(1)Thisdevicemay
notcauseharmfulinterference,and(2)thisdevicemustacceptanyinterferencereceived,includinginterferencethatmay
causeundesiredoperation.
Youarecautionedthatchangesormodificationsnotexpresslyapprovedbythepartyresponsibleforcompliancecouldvoid
theuser'sauthoritytooperatetheequipment.
English:
ThisdevicecomplieswithRSS-210oftheIndustryCanadaRules.Operationissubjecttothefollowingtwoconditions:(1)
Thisdevicemaynotcauseharmfulinterference,and(2)thisdevicemustacceptanyinterferencereceived,including
interferencethatmaycauseundesiredoperation.
French:
CedispositifestconformeàlanormeCNR-210d'IndustrieCanadaapplicableauxappareilsradioexemptsdelicence.Son
fonctionnementestsujetauxdeuxconditionssuivantes:(1)ledispositifnedoitpasproduiredebrouillagepréjudiciable,et
(2) cedispositifdoitacceptertoutbrouillagereçu,ycomprisunbrouillagesusceptibledeprovoquerunfonctionnement
indésirable.
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 7
2.3 Bluetooth®WirelessTechnology 8
2.4 DualSensing 8
2.5 RetrofitInstallations 8
2.6 XCellSensorsOptimizedforFixedGasApplications 9
2.7 TruCalSensingTechnologyforCOandH2SElectrochemicalSensors 9
2.8 SafeSwap 9
2.9 Housing 10
2.10 ComponentOverview 10
2.11 LabelOverview 11
3 Installation 12
3.1 InstallationWarnings-ReadBeforeInstallation 12
3.2 ReviewingShipmentandIdentifyingProductModel 13
3.3 ProductInstallationCheckList 14
3.4 Mounting 14
3.5 InstallingaRemoteSensorJunctionBox 22
3.6 ElectricalPowerConnections 23
4 Operation 35
4.1 Startup 35
4.2 Settings 36
4.3 StatusMenu 59
5 Calibration 59
5.1 CalibrationEquipment 60
5.2 CalibrationFrequency 63
5.3 CalibrationFrequencyforXCelSensorswithTruCal(H2S&COonly) 63
5.4 CalibrationTypes:Zerovs.Span 63
5.5 HowtoZeroCalibrateXCellSensors 64
5.6 HowtoCalibrateXCellSensors 65
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
3 Ultima X5000 Gas Monitor US

7 OrderingInformation 78
7.1 ReplacementParts 78
8 Appendix:Specifications 80
9 Appendix:CalibrationGuideforAdditionalGases 87
10 Appendix:GeneralCertificationInformation 92
11 Appendix:HARTSpecificInformation 94
US Ultima X5000 Gas Monitor 4

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thiswarningcanresultinseriouspersonalinjuryordeath.
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
5 Ultima X5000 Gas Monitor US
1 Safety Regulations

www.hc-sc.gc.ca.
1.2 ProductWarranty
ITEM WARRANTYPERIOD
ULTIMAX5000GasMonitor MSAwarrantsthatthisproductwillbefreefrommechanicaldefectsand
faultyworkmanshipfortheperiodspecifiedinthistableforeach
component,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.
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.
ElectrochemicalSensors 12monthsfromdateofshipment
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.
US Ultima X5000 Gas Monitor 6
1 Safety Regulations

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.
Figure 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.
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.
7 Ultima X5000 Gas Monitor US
2 Description

Figure 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.
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thiswarningcanresultinseriouspersonalinjuryordeath.
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4Operation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.
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.
US Ultima X5000 Gas Monitor 8
2 Description

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negligbleeffectontheoperation
ofthesensor.
2.7 TruCalSensingTechnologyforCOandH2SElectrochemicalSensors
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.
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4.2.1InstrumentSettings.
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
9 Ultima X5000 Gas Monitor US
2 Description

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ComponentOverviewforcomponent
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.
Failuretofollowthiswarningcanresultinseriouspersonalinjuryordeath.
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.
2.10 ComponentOverview
Figure 3 Component Overview
* Only used with M25 bases
US Ultima X5000 Gas Monitor 10
2 Description

2.11 LabelOverview
Serialnumberislocatedwhereshown(highlightedingreen).Actualnumberofdigitsmaybedifferent.
Figure 4 Serial Number Label Figure 5 Board Stack - Position of Label

Figure 6 Digital Sensor - Position of Labels 
Figure 7 XIR Plus - Position of Labels
11 Ultima X5000 Gas Monitor US
2 Description

3 Installation
3.1 InstallationWarnings-ReadBeforeInstallation
WARNING!
• Refertomanualaddendum(P/N10182779)forcertificationinformationandadditionalsafetyinformationbefore
installationandoperation.
• WhenutilizingtheP+FWirelessHARTBulletaccessory,readandunderstandthequickstartguides(P/N10218978
and10218979)andP+FWirelessHARTBulletinstructionmanual(WHA-BLT-F9D0-N-A0-*)beforeinstallingand
using.TheP+FWirelessHARTBulletshallbeinstalledasclosetotheX5000transmitter,junctionboxorJB5000as
possible.
• 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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Figure3forcomponent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H2SDigitalSensormaybeadverselyaffectedbythefollowingsubstances:
○ Alcohols(methanol,ethanol,isoproponal)
○ Nitrogendioxide(NO2)
○ Chlorine(CI2)
○ Paintsolvents(acetone,turpentine,toluene,mineralspirits,etc.)
• TheCODigitalSensormaybeadverselyaffectedbythefollowingsubstances:
○ Alcohols(methanol,ethanol,isoproponal)
○ Paintsolvents(acetone,turpentine,toluene,mineralspirits,etc.)
• TheO2DigitalSensormaybeadverselyaffectedbythefollowingsubstances:
○ LongtermexposuretolowlevelsofAcetylene
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○ Paintsolvents(acetone,turpentine,toluene,mineralspirits,etc.)inhigherconcentrationslargerthan1000ppm
orprolongedexposuretolowerconcentrations
• ProlongedexposureoftheH2SDigitalSensortohumiditylevelsof5%RHorlowerwillresultingasmeasurement
readingsofH2Sthataregreaterthantheactualgasconcentrationpresent.
• ItisnotrecommendedtoexposetheO2,H2SandCODigitalSensorstoenvironmentscontainingOxygenlevels
above30%(v/v)orbelow5%(v/v).TheO2sensorwilloperateat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(P/N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.
• ExposuretocontinuouslevelsofHCNsensorandcanresultinerroneouslylowgasreadings.Thiscanoccurinas
littleas30minutesofexposure.DonotoperateinthepresenceofcontinuouslowlevelbackgroundHCNgas.Use
latchingalarmstoavoidanerroneousalarmclearance.
• SensorsensitivitywillrecoveroverthecourseofseveralhoursonceHCNgasisremoved.Useanindependent
instrumenttoconfirmtheabsenseofHCNgasandallowthesensortoreturntozeropriortorestartingoperations.
• Useofsomeaccessoriesarenotcoveredundertheperformanceapproval.ContactMSAfordetails.
Failuretofollowthiswarningcanresultinseriouspersonalinjuryordeath.
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.
Figure 8 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.
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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3.4.3SensorOrientationforpropersensororientation)
• Mounttransmitterorjunctionboxusingappropriatemountinghardware
• Confirmfreeairflowaroundthesensor
3.4 Mounting
WARNING!
Refertomanualaddendum(P/N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thiswarningcanresultinseriouspersonalinjuryordeath.
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.
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3.4.3 SensorOrientation
WARNING!
MounttheXIRPLUSwiththesensorinletfittingextendedhorizontallyfromthemainenclosure(Figure9)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(Figure10)pointeddownward;otherwise,theinletmaybecomeclogged
withparticulatematterorliquids.
Failuretofollowthiswarningcanresultinseriouspersonalinjuryordeath.
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.Figure9showsthecorrectandincorrectmounting
orientationsfortheULTIMAXIRPLUS.
Figure 9 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.Figure10showsthecorrectandincorrectmountingorientationfordigitalsensors.
Figure 10 Correct and Incorrect Mounting Orientation for Digital Sensors
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.
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Considerthesensordimensionswhenchoosingamountinglocationforthetransmitterorjunctionbox.
Toconnectthesensor:
1. Loosenthesetscrewlocatedonthelidusinga1.5mmAllenwrench.
2. Turnthetransmitterorjunctionboxlidcounterclockwisetoremove
3. Pullonthemetalbailtoremovetheboardstackandexposewiringconnections.
4. 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3.4.3SensorOrientationfordetails).
(Repeat to attach a second sensor to the ULTIMA X5000 transmitter).
5. 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4.2.2SensorSettingsfordetailsonhowtoclearthisfault.
Figure 11 Connecting Sensor to the Stack
NOTE:Sensorconnectorscomepre-wiredonthesensorbody.
Figure 12 Grounding Sensor to Transmitter Housing
6. Verifythesensorconnectorisfirmlyseatedontheterminalboard.
7. Attachthesensor'sgroundtoeitherofthegroundingscrewsinsidetheULTIMAX5000housing.
8. Replacetheboardstacklegsintothefourdepressionsinthehousing.Pushfirmlyontheboardstackwhereindicated
(seeFigure13).
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Figure 13 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.
9. Replacethecoverbyturningclockwise.
10.Tightenthesetscrewlocatedonthelidusinga1.5mmAllenwrench.
3.4.5 IntegratedMountingPoints
TheULTIMAX5000transmittercanbesurfacemountedwithoutanyadditionalbracketsusingtheintegratedmountingtabs.
Figure 14 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.
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Figure 15 Mounting Bracket for ULTIMA X5000 (compatible with ULTIMA XIR PLUS Sensors)
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(P/N10206570).
Figure 16 JB5000 Bracket Attachment
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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.
Figure 17 2" Pipe Mount with U-Bolt
3.4.8 AdjustablePipeMount
AUniversalPipeMountKit(P/N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).
Figure 18 Adjustable Pipe Mount
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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(P/N10179124)andlargeducts20-40"(508-1016mm)indiameter(Part
Number10179321).Theflatductmount(P/N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.
Figure 19 Flat Duct Mount Figure 20 Round Duct Mount
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