MSA Ultima Installation and operating instructions

Ultima®X Gas
Monitors with X3 ®
Technology
Instruction Manual Addendum
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL
HAVE THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece
of complex equipment, this instrument will perform as designed only if it is used and serv-
iced in accordance with the manufacturer’s instructions. OTHERWISE, IT COULD FAIL TO
PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR THEIR
SAFETY COULD SUSTAIN SEVERE PERSONAL INJURY OR DEATH.
The warranties made by Mine Safety Appliances Company 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 others by following them. We encourage our cus-
tomers to write or call regarding this equipment prior to use or for any additional infor-
mation relative to use or repairs.
In North America, to contact your nearest stocking location, dial toll-free 1-800-MSA-INST
To contact MSA International, dial 1-412-967-3354
© MINE SAFETY APPLIANCES COMPANY 2006 - All Rights Reserved
This manual is available on the internet at www.msanet.com
Manufactured by
MSA NORTH AMERICA
P.O. Box 427, Pittsburgh, Pennsylvania 15230
(L) Rev 3 10060413
""WARNING

Table of Contents
Section 1, Typical ModBUS Network
Topography (FIGURE 1-1). . . . . . . . . . . . . . . .1-2
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
RS485 Communications . . . . . . . . . . . . . . . . . . . . . . .1-2
Transmitter Sensor Distance (FIGURE 1-3) . . . . . . . .1-2
Figure 1-1. Typical ModBUS Network Topography .1-3
Table 1-1. Maximum Power Cable Length . . . . . . .1-4
Table 1-2. Transmitter Power Consumption
(7-30 VDC Supply) . . . . . . . . . . . . . . . . . . . . .1-4
Table 1-3. Remote Sensor Power Consumption
(AC or DC Operation) . . . . . . . . . . . . . . . . . . .1-4
Figure 1-2. Typical Communications Wiring Scheme . . . . .1-5
Figure 1-3. Signal-Boost Sensor Diagram . . . . . . . .1-6
Section 2, Typical Communication Cable
Wiring for Signal Boost (FIGURE 2-1) . . . . .2-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Display: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Relays: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Figure 2-1. Typical Communication Cable Wiring
for Signal Boost Option . . . . . . . . . . . . . . . . .2-2
Figure 2-2. Sensor Display Screens . . . . . . . . . . . .2-3
Sensor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Alarm Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Table 2-1. Status Indication Codes . . . . . . . . . . . .2-5
Figure 2-3. Alarm Status Screen . . . . . . . . . . . . . . .2-5
Ultima X Controller or Ultima X Calibrator: . . . . . . . . .2-6
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
ModBUS Communications . . . . . . . . . . . . . . . . . . . . . .2-7
Figure 2-4. Push-button Wiring . . . . . . . . . . . . . . . .2-7
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
i

Section 3, ModBUS . . . . . . . . . . . . . . . . . . . .3-1
ModBUS Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Table 3-1. Supported ModBUS Function Codes . .3-1
Table 3-2. ModBUS Memory Map Overview . . . . .3-2
ModBUS Base Address (Read/Write) . . . . . . . . . . . . .3-2
Table 3-3. ModBUS Bas Address (Read/Write) . . .3-2
Table 3-4. ModBUS Factory Configuration Data
(Read Only) . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Table 3-5. ModBUS User Configuration Data
(Read/Write) . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Table 3-6. Alarm Function Codes - Word 1
(Read/Write at Address Base+137) . . . . . . . .3-5
Table 3-7. Alarm Function Codes - Word 2
(Read/Write at Address Base+138) . . . . . . . .3-5
Table 3-8. ModBUS Device Status (Read only) . . .3-6
Table 3-9. ModBUS General Status Bits
(Read Only at address Base+201) . . . . . . . . .3-8
Table 3-10. ModBUS Fault Status Bits
(Read Only at address Base+202) . . . . . . . . .3-8
Table 3-11. Control Words (Read/Write) . . . . . . . .3-9
Table 3-12. ModBUS Command Word 1
(Read at address Base+301/Write Coils
1 through 16) . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Table 13-13 ModBUS Command Word 2
(Read at address Base+302/Write Coils
17 through 32) . . . . . . . . . . . . . . . . . . . . . . .3-10
Table 3-14. Sensor Type . . . . . . . . . . . . . . . . . . .3-10
Table 3-15. Sensor Engineering Units . . . . . . . . .3-11
Table 3-16. Information Flags Word #1 –
(Read at address Base+254) . . . . . . . . . . . .3-12
Table 3-17. Information Flags Word #2
(Read at address Base+255) . . . . . . . . . . . .3-12
Table 3-18. Information Flags Word #3
(Read at address Base+26) . . . . . . . . . . . . .3-13
Table 3-19. Information Flags Word #4
(Read at address Base+257) . . . . . . . . . . . .3-13
Table 3-20. Alternate Gas Readings
(Read/Write at address Base+258
to Base+260) . . . . . . . . . . . . . . . . . . . . . . . .3-14
ii

1-1
This is an Addendum to the Ultima/Ultima X
Instruction Manual (P/N 10036101)
for use with the Ultima X ModBUS X3Transmitter.

Section 1,
Typical ModBUS Network Topography
(FIGURE 1-1).
As part of the CSA certification, it was verified that the modbus
communication functions of this gas detection instrument do not
adversely affect the gas detection operation and functions of the
instrument. This Certification, however, does not include or imply
certification of the modbus communication function of this gas
instrument.
Sensors
• A network can consist of up to 31 monitors.
• Each monitor can support up to three sensors.
• Total number of sensors is 93.
Wiring
Power
• Maximum power cable length depends on sensor configuration and
wire gauge (TABLES 1-1, 1-2 and 1-3).
RS485 Communications
• Three-wire cable, 22 AWG is labeled:
• A = Transmit + / Receive +
• B = Transmit - / Receive -
• C = Common
• Typical Communications Wiring Scheme
(see FIGURE 1-2)
• Maximum RS-485 communications cable length:
• Trunk: 3000 feet
• Branch: 60 feet
• Use line termination devices to match communication line
characteristics (typically 120 Ohms).
Transmitter Sensor Distance (FIGURE 1-3)
• Maximum transmitter-sensor distance is normally 100 feet.
• The distance is extended to 3000 feet if the signal boost option is
installed.
• This option requires the sensor to be locally powered.
• It is possible to selectively use this feature on a per-sensor
basis.
1-2

Figure 1-1. Typical ModBUS Network Topography
1-3

Table 1-1. Maximum Power Cable Length
CONFIGURATION MAXIMUM POWER CABLE LENGTH (IN FEET)
(WITH NOMINAL 24-VDC TRANSMITTER SUPPLY)
CATALYTIC XIR E-CHEM 16 AWG CABLE 14 AWG 12 AWG
[4.2 OHM [2.6 OHM [1.8 OHM
PER 1K FT.] PER 1K FT.] PER 1K FT.]
NO RELAY NO RELAY NO RELAY
RELAYS- OPTION- RELAYS OPTION RELAYS OPTION
0 0 3 4500 3500 7500 5500 10,000 7,500
0 2 1 2000 1500 2750 2500 4,000 3,500
0 1 2 3000 2250 4500 3500 6,250 5,000
1 0 2 3500 2750 5500 4250 7,500 6,000
1 1 1 2000 1500 2750 2500 4,000 3,500
2 0 1 2500 1850 3500 3000 5,000 4,000
3 0 0 2000 1500 2750 2500 3,750 3,500
Daisy chaining power to multiple sensors is not recommended.
Table 1-2. Transmitter Power Consumption (7-30 VDC Supply)
CONFIGURATION MAX. POWER MAX. POWER
CONSUMPTION CONSUMPTION
CATALYTIC XIR* E-CHEM* WITH RELAYS CLOSED WITH RELAYS OPEN
0 0 3 2.5 W 1.5W
0 2 1 9.5 W 8.5W
0 1 2 7.0 W 6.0 W
1 0 2 6.0 W 5.0 W
1 1 1 6.5 W 5.5 W
2 0 1 8.0 W 7.0 W
3 0 0 10.0 W 9.0 W
*Combinations shown represent maximum loads that may be powered from one
transmitter without remote power.
NOTE: Only use single catalytic or XIR sensor configuration with 7 W power supply.
If at least one sensor is remote with signal boost or has remote power, any combination is available.
Recommended power supply selection is for operation not to exceed 65% of capacity.
See Installation Outline Drawings for details.
Table 1-3.
Remote Sensor Power Consumption (AC or DC Operation)
SENSOR TYPE MAXIMUM POWER CONSUMPTION
Catalytic* 4.5 W
XIR* 5.0 W
E-Chem 1.5 W
*The input for the 240 VAC Remote XIR and XE Sensors shall be additionally limited to
3.5 A.
1-4

Figure 1-2. Typical Communications Wiring Scheme
1-5

Figure 1-3. Signal-Boost Sensor Diagram
1-6

Section 2,
Typical Communication Cable Wiring
for Signal Boost (FIGURE 2-1)
Operation
Display:
• Displays sensor type and gas level for each sensors
• Cycles through the sensors
• Sensor number graphic identifies sensor number
(see FIGURE 2-2)
• Latches on an Alarm or Fault condition and requires user
acknowledgment prior to resuming cycling
• If multiple conditions exist, reveals the subsequent alarm/fault
condition when one condition is acknowledged
• Resumes cycling through display screens when all conditions are
acknowledged.
• Alarm and fault conditions are indicated by alarm and the
corresponding number of the alarm level(s) that are activated
Relays:
• Gas processing and alarm activation continues even when a
display is locked on a screen
• Are common to all sensors by default
• Can be assigned specifically to a sensor by enabling only one level
of alarm for each sensor
• This may be accomplished through an Ultima X Controller
(see Section 2, "Calibration") consistent with the existing
Ultima X procedures or through a ModBUS controller
• Form C contacts, 5 A resistive, 30 VDC, 250 VAC
• May be configured as
• Normally energized/de-energized
• Increasing/decreasing level alarm
• Latching/non-latching
2-1

Figure 2-1. Typical Communication Cable Wiring for Signal
Boost Option
SIG + SIG + SIG +SIG - SIG - SIG -
COMMON COMMON COMMON
Ultima X3 Transmitter
Sensor 1
Sensor 1 Sensor 2Sensor 3
SIG +
SIG -
COMMON
L1 L2
GND
DC +
DC -
SIG +
SIG -
COMMON
DC +
DC -
SIG +
SIG -
COMMON
Sensor 2
Sensor 3
Local AC power
with AC power option
Local DC power
with DC power option
Local DC
power with
DC power
option
2-2

Figure 2-2. Sensor Display Screens
2-3

Sensor:
• Automatically recognized when connected to a transmitter
• When removed, causes a "Sensor Missing" fault; this can be
corrected by:
• Reconnecting a sensor to that position or
• Manually taking the sensor 'off-line' via:
• Ultima X Controller, by sending a sensor disable command
• ModBUS command write to a control register.
• A missing sensor or unused sensor position returns a gas value of
-99.9 in response to a ModBUS request for gas level value starting
at address base +207.
Alarm Status Screen
(FIGURE 2-3)
In the North American version of the Ultima X with X3 Technology, a
screen will appear when a combustible sensor crosses 50%, 60% or
90% of the full-scale range.
• This screen:
• will override all sensor data or fault screens and will clear when
all sensors are below 50% of scale.
• can be acknowledged by the operator; the:
• instrument will go back to normal display operation until the
sensor or any other sensor crosses 50%, 60% or 90% of
scale
• normal operation status screen will display again.
• can be acknowledged through the:
• Ultima X Controller
• Pushbutton or
• MODBUS interface.
NOTE: All IR inputs will be functional and appropriate display
screens will display for the received IR message.
2-4

Table 2-1. Status Indication Codes
CODE INDICATION
“d” Sensor position disabled
“F” Sensor position in a fault state
“N” Sensor position in normal operation, below 50% of range, and not in alarm
“A” Sensor position in alarm
“L” Sensor position at or above 50% of range
“M” Sensor position at or above 60% of range
“H” Sensor position at or above 90% of range
• The SENSOR, ALARM #1, #2, #3 indicators will still function as
normal cycling though each sensor position. This allows the:
• use of the IR signal to be received for each sensor position
• user to see what alarms are active for each sensor when the
status screen is displayed.
NOTE: In the CSA mode, the display (alarm/fault) locking feature will
be removed. This will allow the display to continuously cycle
through the three sensors. In doing so, the alarm flags will be
displayed as the instrument cycles, preventing the need to dis-
play the status screen upon alarm.
A. Indicates the status of Sensor #1.
B. Indicates the status of Sensor #2.
C. Indicates the status of Sensor #3.
Figure 2-3. Alarm Status Screen
2-5

Ultima X Controller or Ultima X Calibrator:
• May be used to send commands to display data or set
configurations consistent with existing Ultima X procedures
• May be sent at any time for transmitter-specific commands, such
as address, baud rate, etc.
• Sensor-specific commands
(such as calibration initiation or span value) must be sent while the
sensor data (sensor type or gas levels) is displayed
Calibration
Calibration is performed via the:
•Ultima X Controller
• Sends a zero or span command
• Sensor calibration depends on the sensor number showing on
the display when the command is received.
• Push-button
• Depends on the sensor number showing on the display when
the command is received.
• Press and release push-button to acknowledge any conditions
• With the desired sensor data (sensor or gas level) on the
display, press the push-button to activate a calibration
• Calibration function depends on length of time that the push-
button is pressed
• 5 seconds: zero calibration
• 10 seconds: span calibration
• 20 seconds: factory initial calibration
• Push-button may be factory/user-installed (FIGURE 2-4).
• See Installation Outline Drawings for details.
2-6

•ModBUS Port
• See ModBUS data table definition in this addendum.
During the calibration process, the transmitter is in
Maintenance mode, all alarming is inhibited for all sensors,
and transmitter will not alert user to potential hazardous sit-
uations.
• During the calibration of a sensor, a ModBUS request for the gas
level returns the actual value. The other sensors on that specific
transmitter are not active. A gas level of -99.9 will be returned to
indicate that.
ModBUS Communications
Baud rate and data format defaults per data table specification are
adjustable by using a:
• Hand-held Controller or
• ModBUS command.
Each transmitter:
• Is a slave on the communications network
• Must have a unique address and serial format compatible with
transmitter configuration.
""WARNING
Figure 2-4. Push-button Wiring
2-7

Section 3,
ModBUS
ModBUS Addressing
The ModBUS slave address has a valid range of 1-247.
• 247 is the default value.
This address may be set by:
• The Ultima X Controller:
• Send an address command with the desired value.
• The Ultima X Calibrator:
• Press the ADDRESS button once to display the current setting.
• The ZERO button increments the address number
• The SPAN button decrements the address number
• Range for Calibrator is 1 - 32; use Controller for other
addresses
• Press the ADDRESS button again to save the new address.
• A ModBUS controller by writing to the corresponding register in the
data table.
ModBUS Communications
• The communications protocol is ModBUS RTU over an RS-485
hardware network.
• The default settings for communications parameters are 19200
baud and even parity.
• The stop bits are fixed at 1 stop bit.
• For data types that are larger than one word, the most significant
word is located in the first register (big-endian).
Table 3-1. Supported ModBUS Function Codes
FUNCTION
NUMBER DESCRIPTION
3 Read Holding Registers
5 Write Single Coil
6 Write Single Register
16 Write Multiple Registers
3-1

Table 3-2. ModBUS Memory Map Overview
The Modbus port allows for access to a significant amount of information which may be
necessary for your system integration requirements. As a minimum, the gas readings and
fault status registers should be polled.
DESCRIPTION START END SIZE IN ACCESS
ADDRESS ADDRESS WORDS
ModBUS Data Table
Start Base Address 1000 1000 1 Read/Write
Factory Configuration
Data Base+1 Base+18 18 Read Only
User Configuration
Data Base+101 Base+148 48 Read/Write
Status Information Base+201 Base+253 53 Read Only
Control Words Base+301 Base+302 2 Read/Write
ModBUS Base Address (Read/Write)
The ModBUS base address register is located at address 1000 and has
a default value of 40,000.
• This may be changed by writing a new value within the permissible
range to that address.
• Subsequent addresses must take this new base address into
consideration.
• The base address may be changed by writing to address 1000,
regardless of its contents.
Table 3-3. ModBUS Bas Address (Read/Write)
DESCRIPTION ADDRESS POSSIBLE VALUES
ModBUS Data
Table Base Address 1000 1000 - 60,000
(default 40,000)
• For systems that use five-digit addressing, 4XXXX:
• If the first digit is an internal system requirement and does not
appear in the communications packet, write the value 1000 to
address 41000. The base address is now 41000 and the first
valid address is 41001.
• If all five digits appear in the communications packet, the
default base address is 40000 and the first valid address is
40001.
3-2

• For systems that use six-digit addressing, 4XXXXX:
• The first digit is an internal system requirement and does not
appear in the communications packet. The base address is
440000, and the first valid address is 440001.
Table 3-4. ModBUS Factory Configuration Data (Read Only)
DESCRIPTION ADDRESS POSSIBLE VALUES
Device Type Base+1 3(Ultima X3 US)
4(Ultima X3 Europe)
Firmware Version Base+2 0..32767 Integer,
divide by 100 for range
00.00 to 99.99
Relays Option Installed Base+3 0-Relays not installed,
1-Relays installed
Reserved for future use Base+4
Date of Mfg Year, Sensor 1 Base+5 20XX
Date of Mfg Month, Sensor 1 Base+6 1..12
Date of Mfg Day, Sensor 1 Base+7 1..31
Date of Mfg Year, Sensor 2 Base+8 20XX
Date of Mfg Month, Sensor 2 Base+9 1..12
Date of Mfg Day, Sensor 2 Base+10 1..31
Date of Mfg Year, Sensor 3 Base+11 20XX
Date of Mfg Month, Sensor 3 Base+12 1..12
Date of Mfg Day, Sensor 3 Base+13 1..31
Full Scale Range-
Default Sensor 1 Base+14 Single Precision Float
Full Scale Range-
Default Sensor 2 Base+16 Single Precision Float
Full Scale Range-
Default Sensor 3 Base+18 Single Precision Float
3-3

Table 3-5. ModBUS User Configuration Data (Read/Write)
DESCRIPTION ADDRESS POSSIBLE VALUES
ModBUS Slave Address Base+101 1..247
Baud Rate Code Base+102 0 - 1200, 1 - 2400
2 - 4800, 3 - 9600
4 - 19200 (default)
Parity Code Base+103 0 - Even (default)
1 - Odd
2 - None
For future use Base+104
For future use Base+105
For future use Base+106
Full Scale Range, Sensor 1 Base+107 Single Precision Float
Full Scale Range, Sensor 2 Base+109 Single Precision Float
Full Scale Range, Sensor 3 Base+111 Single Precision Float
Span Gas Value, Sensor 1 Base+113 Single Precision Float
Span Gas Value, Sensor 2 Base+115 Single Precision Float
Span Gas Value, Sensor 3 Base+117 Single Precision Float
Alarm 1 Setpoint, Sensor 1 Base+119 Single Precision Float
Alarm 1 Setpoint, Sensor 2 Base+121 Single Precision Float
Alarm 1 Setpoint, Sensor 3 Base+123 Single Precision Float
Alarm 2 Setpoint, Sensor 1 Base+125 Single Precision Float
Alarm 2 Setpoint, Sensor 2 Base+127 Single Precision Float
Alarm 2 Setpoint, Sensor 3 Base+129 Single Precision Float
Alarm 3 Setpoint, Sensor 1 Base+131 Single Precision Float
Alarm 3 Setpoint, Sensor 2 Base+133 Single Precision Float
Alarm 3 Setpoint, Sensor 3 Base+135 Single Precision Float
Alarm Function Word 1 Base+137 0..32767, See detail below
Alarm Function Word 2 Base+138 0..32767, See detail below
Average Time Interval Base+139 1,8 or 24
Current Date - Year Base+140 20XX
Current Date - Month Base+141 1..12
Current Date - Day Base+142 1..31
Current Time -Hour Base+143 1..24
Current Time - Minute Base+144 0..59
Current Time - Second Base+145 Read Only
Gas Table Number
Sensor 1 (XIR) Base+146 1 Methane, 2 Propane
3 Ethane, 4 Butane
5 Pentane, 6 Hexane
7 Cyclopentane, 8 Ethylene
Gas Table Number
Sensor 2 (XIR) Base+147 Same as above
Gas Table Number
Sensor 3 (XIR) Base+148 Same as above
3-4