MSA ULTIMA XL Series User manual

Operating Manual
ULTIMA XL®Series
ULTIMA XT®Series
Gas Monitors
Order No.: 10092331/00

MSA AUER GmbH
Thiemannstrasse 1
D-12059 Berlin
Germany
© MSA AUER GmbH. All rights reserved

Declaration of ConformityMSA
ULTIMA XL/ULTIMA XT
GB 3
Declaration of Conformity
Manufactured by: Mine Safety Appliances Company
1000 Cranberry Woods Drive
Cranberry Township, PA 16066 USA
European authorized representative:
MSA AUER GmbH
Thiemannstrasse 1
D-12059 Berlin
We declare that the product
ULTIMA XL Control Unit
based on the EC-Type Examination Certificates:
FM07ATEX0001X and FM07ATEX0004X
complies with the ATEX directive 94/9/EC, Annex III. Quality Assurance Notification
complying with Annex IV of the ATEX Directive 94/9/EC has been issued by INERIS of
France , Notified Body number: 0080
The product is in conformance with the EMC directive 89/336/EC, changed by
Directive 91/263/EC, 92/31/EC, 93/68/EC, with the following harmonized norms or nor-
mative documentation:
EN 50270 Type 2 EN 61000-6-3 EN 61000-6-4
We further declare that the product complies with the provisions of LVD
Directive 73/23/EC as amended by Directives 93/68/EC, with the following harmonized
norms or normative documentation:
EN 61010-1
MSA AUER GmbH
Dr. Axel Schubert
R&D Instruments
Berlin, July 2007

MSADeclaration of Conformity
ULTIMA XL/ULTIMA XT
4GB
Declaration of Conformity
The manufacturer or his in the community established authorized representative
MSA AUER GmbH
Thiemannstrasse 1
D-12059 Berlin
declares that the product
ULTIMA XT
complies with the EMC directive 89/336/EC, changed by Directive 91/263/EC,
92/31/EC, 93/68/EC, with the following harmonized norms or normative documenta-
tion:
EN 50270 Type 2 EN 61 000 - 6 – 3
MSA AUER GmbH
Dr. Axel Schubert
R&D Instruments
Berlin, July 2007

Declaration of ConformityMSA
ULTIMA XL/ULTIMA XT
GB 5
Declaration of Conformity
Manufactured by: Mine Safety Appliances Company
1000 Cranberry Woods Drive
Cranberry Township, PA 16066 USA
European authorized representative:
MSA AUER GmbH
Thiemannstrasse 1
D-12059 Berlin
We declare that the product
ULTIMA XIR Sensor
A-UltX - Sens - a - b – 0
a = Gas Type: 38, 39, 58 or 59
b = Enclosure Type: 9 or 10
based on the EC-Type Examination Certificate: FM07ATEX0032X
complies with the ATEX directive 94/9/EC, Annex III. Quality Assurance Notification
complying with Annex IV of the ATEX Directive 94/9/EC has been issued by INERIS
of France , Notified Body number: 0080
The product is in conformance with the EMC directive 89/336/EC, changed by
Directive 91/263/EC, 92/31/EC, 93/68/EC, with the following harmonized norms or nor-
mative documentation:
EN 50270 Type 2 EN 61000-6-3 EN 61000-6-4
We further declare that the product complies with the provisions of LVD
Directive 73/23/EC as amended by Directives 93/68/EC, with the following harmonized
norms or normative documentation:
EN 61010-1
MSA AUER GmbH
Dr. Axel Schubert
R&D Instruments
Berlin, July 2007

MSADeclaration of Conformity
ULTIMA XL/ULTIMA XT
6GB
Declaration of Conformity
Manufactured by: Mine Safety Appliances Company
1000 Cranberry Woods Drive
Cranberry Township, PA 16066 USA
European authorized representative:
MSA AUER GmbH
Thiemannstrasse 1
D-12059 Berlin
We declare that the product
ULTIMA XE Sensor
A-UltX - Sens - a - b – 0
a = Gas Type: 31, 32, 33, 51, 52 or 53
b = Enclosure Type: 1 or 8
based on the EC-Type Examination Certificate: FM07ATEX0031X
complies with the ATEX directive 94/9/EC, Annex III. Quality Assurance Notification
complying with Annex IV of the ATEX Directive 94/9/EC has been issued by INERIS of
France , Notified Body number: 0080
The product is in conformance with the EMC directive 89/336/EC, changed by
Directive 91/263/EC, 92/31/EC, 93/68/EC, with the following harmonized norms or nor-
mative documentation:
EN 50270 Type 2 EN 61000-6-3 EN 61000-6-4
We further declare that the product complies with the provisions of LVD
Directive 73/23/EC as amended by Directives 93/68/EC, with the following harmonized
norms or normative documentation:
EN 61010-1
MSA AUER GmbH
Dr. Axel Schubert
R&D Instruments
Berlin, July 2007

Table of ContentsMSA
ULTIMA XL/ULTIMA XT
GB 7
Table of Contents
1 Safety Regulations ................................................................................................. 9
1.1 Correct Use .................................................................................................. 9
1.2 Liability Information ....................................................................................... 9
1.3 Safety and Precautionary Measures to be Adopted ................................... 10
1.4 MSA Permanent Instrument Warranty ........................................................ 12
2 Introduction .......................................................................................................... 14
2.1 General Description .................................................................................... 14
2.2 Identifying Your Unit ................................................................................... 14
2.3 Installing Your Gas Monitor ........................................................................ 19
2.4 Installing the ULTIMA XT Gas Monitor ....................................................... 20
2.5 Installing the ULTIMA XL Gas Monitor ....................................................... 21
2.6 Installing the ULTIMA XIR Gas Monitor ...................................................... 22
2.7 Electrical Connections for ULTIMA X Gas Monitors ................................... 23
2.8 Wiring for all Models ................................................................................... 23
2.9 ULTIMA XIR ............................................................................................... 26
2.10 Installing the ULTIMA X Remote Sensor Module ....................................... 29
2.11 Electrical Connections for the ULTIMA X Series Remote Sensor Module .. 29
3 Start-up and Calibration ...................................................................................... 31
3.1 Initial Start-up ............................................................................................. 31
3.2 Calibration Basics ....................................................................................... 33
3.3 ULTIMA X Series Gas Monitor Calibration Procedure ............................... 35
3.4 Span Gas Values ........................................................................................ 36
3.5 ULTIMA X Series Gas Monitor Calibration ................................................. 46
3.6 Standard Calibration ................................................................................... 47
3.7 Oxygen Calibration ..................................................................................... 50
3.8 XIR Calibration ........................................................................................... 51
3.9 Optional Push-button Calibration ................................................................ 52

MSATable of Contents
ULTIMA XL/ULTIMA XT
8GB
3.10 Calibration Using a HART® Communicator ............................................... 52
3.11 Standard Calibration Procedures ............................................................... 55
3.12 Initial Calibration Procedures ...................................................................... 58
3.13 User [Stepped] Calibration Procedures ...................................................... 58
3.14 Sample Calibration Display Screens .......................................................... 61
3.15 Troubleshooting .......................................................................................... 74
4 Specifications ....................................................................................................... 80
4.1 HART Field Device Specification ................................................................ 89
4.2 Product Overview ....................................................................................... 90
4.3 Product Interfaces ...................................................................................... 91
4.4 Universal Commands ................................................................................. 96
4.5 Common-Practice Commands ................................................................... 96
4.6 Performance ............................................................................................. 121
4.7 Capability Checklist .................................................................................. 123
4.8 Default Configuration ................................................................................ 124
4.9 Marking, Certificates and Approvals according to the
Directive 94/9/EC [ ATEX ] ....................................................................... 125
5 Maintenance ....................................................................................................... 131
5.1 General ..................................................................................................... 131
5.2 ULTIMA XIR Cleaning Procedure ............................................................. 131
6 Ordering Information ......................................................................................... 136
7 Appendix ............................................................................................................. 141
7.1 Installation Drawings ............................................................................... 141

Safety RegulationsMSA
ULTIMA XL/ULTIMA XT
GB 9
1 Safety Regulations
1.1 Correct Use
The ULTIMA XL/ULTIMA XT Series are fixed gas monitors for measuring toxic and
combustible gases as well as oxygen. They are suitable for outdoor and indoor ap-
plications without limitations, e.g. offshore industry, chemical and petrochemical in-
dustry, water and sewage industry. Using sensors, the instruments test the ambient
air and trigger the alarm as soon as the gas exceeds a specific concentration level.
It is imperative that this operating manual be read and observed when using the
ULTIMA XL/ULTIMA XT Series of gas monitors. In particular, the safety instruc-
tions, as well as the information for the use and operation of the apparatus, must be
carefully read and observed. Furthermore, the national regulations applicable in the
user's country must be taken into account for a safe use.
Alternative use, or use outside this specification will be considered as non-compli-
ance. This also applies especially to unauthorised alterations to the apparatus and
to commissioning work that has not been carried out by MSA or authorised persons.
1.2 Liability Information
MSA accepts no liability in cases where the product has been used inappropriately
or not as intended. The selection and use of the product are the exclusive respon-
sibility of the individual operator.
Product liability claims, warranties also as guarantees made by MSA with respect
to the product are voided, if it is not used, serviced or maintained in accordance with
the instructions in this manual.
Danger!
This product is supporting life and health. Inappropriate use, mainte-
nance or servicing may affect the function of the device and thereby se-
riously compromise the user’s life.
Before use the product operability must be verified. The product must
not be used if the function test is unsuccessful, it is damaged, a compe-
tent servicing/maintenance has not been made, genuine MSA spare
parts have not been used.

MSASafety Regulations
ULTIMA XL/ULTIMA XT
10 GB
1.3 Safety and Precautionary Measures to be Adopted
(1) The ULTIMA X Series Gas Monitors described in this manual must be in-
stalled, operated and maintained in strict accordance with their labels, cau-
tions, warnings, instructions, and within the limitations stated.
(2) The ULTIMA X Series Gas Monitor is designed to detect gases or vapors in
air. It cannot measure the concentration of gases or vapors in steam or inert
or oxygen-deficient atmospheres. The oxygen sensor can measure oxygen-
deficient atmospheres.
(3) Electrochemical sensors are sealed units which contain a corrosive electro-
lyte. Should a sensor develop leakage, it must be immediately removed from
service; then, remove it from the sensing head and discard it properly. Caution
must be exercised so that the electrolyte does not contact skin, eyes, clothing
or circuitry; otherwise, serious personal injury [burns] and/or equipment dam-
age may result.
(4) Use only genuine MSA replacement parts when performing any maintenance
procedures provided in this manual. Failure to do so may seriously impair in-
strument performance. Repair or alteration of the ULTIMA X Series Gas Mon-
itor, beyond the scope of these maintenance instructions or by anyone other
than an authorized MSA service personnel, could cause the product to fail to
perform as designed and persons who rely on this product for their safety
could sustain serious personal injury or loss of life.
(5) General-purpose [GP] ULTIMA X Series Gas Monitors can be a source of ig-
nition. Install, locate, and operate GP models in a non-hazardous area and in
accordance with all applicable codes. If a hazardous area must be monitored,
use only an explosion-proof/ flameproof ULTIMA X Series Gas Monitor model.
(6) The ULTIMA XIR Infrared combustible gas monitor detects the presence of
most combustible gases by identifying the difference in the amount of infrared
light energy absorbed during the presence of these gases. This monitor, how-
ever, does NOT detect the presence of hydrogen gas and must never be used
to monitor for hydrogen gas.
(7) The standard ULTIMA XIR Infrared Combustible Gas Monitor does not detect
the presence of acetylene gas and the presence of acetylene gas will degrade
sensor performance. Custom-built acetylene sensors are available through
your MSA representative.
Attention!
The following safety instructions must be observed implicitly. Only in this
way can the safety and health of the individual operators, and the correct
functioning of the instrument, be guaranteed.

Safety RegulationsMSA
ULTIMA XL/ULTIMA XT
GB 11
(8) As with all gas monitors of these types, high levels of, or long exposure to, cer-
tain compounds in the tested atmosphere could contaminate the sensors. In
atmospheres where an ULTIMA X Series Gas Monitor may be exposed to
such materials, calibration must be performed frequently to ensure that oper-
ation is dependable and display indications are accurate.
(9) The ULTIMA X Series Gas Monitor must not be painted. If painting is done in
an area where a Monitor is located, care must be exercised to ensure that
paint is not deposited on the sintered, metal flashback arrestor in the inlet fit-
ting of the ULTIMA X Series Gas Monitor, if so equipped. Such paint deposits
would interfere with the diffusion process, whereby a sample of the atmos-
phere being monitored diffuses into the Monitor.
(10) The only absolute method to ensure proper overall operation of an ULTIMA X
Series Monitor is to check it with a known concentration of the gas for which it
has been calibrated. Consequently, calibration checks must be included as
part of the routine inspection of the system.
(11) Protect the ULTIMA X Series Gas Monitor from extreme vibration. Do not
mount the sensing head in direct sunlight as this may cause overheating of the
sensor.

MSASafety Regulations
ULTIMA XL/ULTIMA XT
12 GB
1.4 MSA Permanent Instrument Warranty
Warranty
Seller warrants that this product will be free from mechanical defect or faulty work-
manship for
- Gas monitor: eighteen [18] months from date of shipment or one [1] year from
installation, whichever occurs first;
- Oxygen, Toxic or Catalytic Combustible Sensor: eighteen [18] months from date
of shipping or one [1] year from installation, whichever occurs first;
- IR sensor source, ten [10] years from date of shipment. All other IR compo-
nents: Two [2] years from date of shipment.
This warranty is applicable provided the product is maintained and used in accord-
ance with Seller's instructions and/or recommendations. This warranty does not ap-
ply to expendable or consumable parts, whose normal life expectancy is less than
one [1] year.
The Seller shall be released from all obligations under this warranty in the event re-
pairs 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 prod-
uct. No agent, employee or representative of the Seller has any authority to bind the
Seller to any affirmation, representation or warranty concerning the goods sold un-
der this contract. Seller makes no warranty concerning components or accessories
not manufactured by the Seller, but will pass onto the Purchaser all warranties of
manufacturers of such components. THIS WARRANTY IS IN LIEU OF ALL OTH-
ER WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, AND IS STRICT-
LY LIMITED TO THE TERMS HEREOF. SELLER SPECIFICALLY DISCLAIMS
ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICU-
LAR PURPOSE.

Safety RegulationsMSA
ULTIMA XL/ULTIMA XT
GB 13
Exclusive Remedy
It is expressly agreed that Purchaser's sole and exclusive remedy for breach of the
above warranty, for any tortious conduct of Seller, or for any other cause of action,
shall be the repair and/ or replacement at Seller's option, of any equipment or parts
thereof, which after examination by Seller is proven to be defective. Replacement
equipment and/ or parts is provided at no cost to Purchaser, F.O.B. Seller's Plant.
Failure of Seller to successfully repair any nonconforming product shall not cause
the remedy established hereby to fail of its essential purpose.
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 dam-
ages or losses of any kind whatsoever, including but not limited to, loss of anticipat-
ed 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 oth-
er cause of action against seller.

MSAIntroduction
ULTIMA XL/ULTIMA XT
14 GB
2 Introduction
2.1 General Description
The ULTIMA X Gas Monitor is designed to sample the environment where mounted
and alert you to potentially dangerous levels of your target gas, depending on your
particular model. The unit is factory-calibrated and shipped ready for installation.
2.2 Identifying Your Unit
The ULTIMA XT Gas Monitor is housed in a rugged, plastic general-purpose enclo-
sure [ÆFig. 1].
Fig. 1 General-Purpose ULTIMA XT Monitor
The ULTIMA XL Gas Monitor is housed in a 316 stainless steel explosion-proof/
flameproof enclosure [ÆFig. 2].

IntroductionMSA
ULTIMA XL/ULTIMA XT
GB 15
Fig. 2 Flameproof ULTIMA XL Monitor

MSAIntroduction
ULTIMA XL/ULTIMA XT
16 GB
The ULTIMA XIR Gas Monitor is housed in a 316 stainless steel flameproof enclo-
sure [ÆFig. 3].
Fig. 3 Flameproof ULTIMA XL with IR Monitor
Remote Sensor Models are shown in ÆFig. 4, ÆFig. 5 and ÆFig. 6.

IntroductionMSA
ULTIMA XL/ULTIMA XT
GB 17
Fig. 4 General-Purpose XT Remote Sensor Model

MSAIntroduction
ULTIMA XL/ULTIMA XT
18 GB
Fig. 5 Flameproof XL Remote Sensor Model
Fig. 6 Flameproof XIR Remote Sensor Model'

IntroductionMSA
ULTIMA XL/ULTIMA XT
GB 19
To determine your sensor type and options, check the shipping carton. Checked
items are included in the carton. Also check the sensor ID label located on the sen-
sor module. The carton label identifies:
- Type of unit supplied [Gas Monitor, Gas Monitor Less Sensor, or
Sensing Module]
- Type of gas [combustible gas, toxic gas or oxygen]
- Range [% LEL, PPM [parts per million], or %]
- Output [3 wire, 4 to 20 mA]
2.3 Installing Your Gas Monitor
Generally, the ULTIMA X Series Gas Monitors or remote sensing module should be
mounted close to the area where a leak is likely to occur or where the gas is expect-
ed. Install the ULTIMA X Series Gas Monitors or the remote sensing module at a
high level [ceiling] or low level [floor], depending on the density of the gas most likely
to be found.
For further information see installation drawings in the appendix.
Attention!
Mount the ULTIMA Gas Monitor or the remote sensor module with the
sensor inlet fitting [ÆFig. 1, ÆFig. 2, ÆFig. 4 or ÆFig. 5] pointed
downward; otherwise, the inlet may become clogged with particulate
matter or liquids.
Mount the ULTIMA XIR Gas Monitor or Remote Sensing Module with the
sensor inlet fitting extended horizontally from the main enclosure
ÆFig. 3 and ÆFig. 6] to help prevent the build-up of particulate or liquid
matter on the monitor's optical surfaces.
Do not paint the ULTIMA X Series Gas Monitors. If painting is done in an
area where a sensor is located, exercise CAUTION to ensure paint is not
deposited on the sensor inlet fitting. Such paint deposits would interfere
with the diffusion process, whereby a sample of the monitored atmos-
phere diffuses into the sensor. In addition, solvents in the paint may
cause an alarm condition to occur.
Protect the ULTIMA X Series Gas Monitors from extreme vibration. Do
not mount sensing head in direct sunlight as this may cause overheating
of the sensor.

MSAIntroduction
ULTIMA XL/ULTIMA XT
20 GB
2.4 Installing the ULTIMA XT Gas Monitor
Remove lid and drill enclosure for power/signal cable entry. Use one of the following
methods to mount the general-purpose ULTIMA XT Gas Monitor/Less Sensor or
the ULTIMA XT Gas Monitor.
- Using customer-installed wiring holes, install the ULTIMA XT Gas Monitor to the
end of rigid conduit.
- Use mounting holes in the corners of the ULTIMA XT enclosure to mount direct-
ly to a wall.
Warning!
Do not locate the general-purpose enclosure models in an area which
may contain a flammable mixture of gas and air; otherwise, an explosion
may occur. The general-purpose ULTIMA X Series Gas Monitors can be
a source of ignition and must not be mounted in an area where a flam-
mable mixture of combustible gas and air may become present; other-
wise, an explosion may occur. If such a location must be monitored, use
a flameproof gas monitor.