MSA Ultima X Series User manual

Ultima®X Series Gas
Monitors
instruction manual
"WARNING
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, the unit will perform as
designed only if it is installed, used and serviced 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 customers to write or call regarding this equipment
prior to use or for any additional information relative to use or repairs.
In 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.
This manual is available on the internet at www.msanet.com
© MINE SAFETY APPLIANCES COMPANY 2005 - All Rights Reserved
Manufactured by
MSA INSTRUMENT DIVISION
P.O. Box 427, Pittsburgh, Pennsylvania 15230
(L) Rev 3 10036101

MSA Instrument Warranty
1. Warranty- Seller warrants that this product will be free from
mechanical defect or faulty workmanship for a period of
eighteen (18) months from date of shipment or one (1)
year from installation, whichever occurs first, provided it is
maintained and used in accordance with Seller’s
instructions and/or recommendations. This warranty does
not apply to expendable or consumable parts whose
normal life expectancy is less than one (1) year such as,
but not limited to, non-rechargeable batteries, sensor
elements, filter, lamps, fuses etc. 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 the
goods sold under this contract. 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.
2. 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 will be
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.
3. 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 nonoperation of the goods. This exclusion is
applicable to claims for breach of warranty, tortious
conduct or any other cause of action against seller.

General Warnings and Cautions
"!WARNING
1. The Ultima X Series Gas Monitors described in this manual
must be installed, operated and maintained in strict
accordance with their labels, cautions, 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 electrolyte. 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 damage 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 instrument
performance. Repair or alteration of the Ultima X Series
Gas Monitor, 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
death.
5. 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 flammable mixture of combustible gas and air
may become present; otherwise, an explosion may occur.
If such a location must be monitored, use an
explosion-proof 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,

however, does NOT detect the presence of hydrogen gas
and must never be used to monitor for hydrogen gas.
7. The Ultima XIR Infrared Combustible Gas Monitor does not
detect the presence of acetylene gas and the presence of
acetylene gas will degrade sensor performance.
Failure to follow the above can result in serious personal injury
or death.
"CAUTION
1. As with all gas monitors of these types, high levels of, or
long exposure to, certain 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 operation is
dependable and display indications are accurate.
2. 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 fitting of the Ultima X Series Gas Monitor, if so
equipped. Such paint deposits would interfere with the
diffusion process, whereby a sample of the atmosphere
being monitored diffuses into the Monitor.
3. 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.
4. 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.
Failure to follow the above can result in injury, product damage
and/or an unsafe condition.

Table of Contents
Chapter 1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Identifying Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-1. General-Purpose Ultima XA Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-2. Explosion-Proof Ultima XE Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-3. Explosion-Proof Ultima XIR Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-4. General-Purpose XA Remote Sensor Model . . . . . . . . . . 1-2
Figure 1-5. Explosion-Proof XE Remote Sensor Model . . . . . . . . . . . 1-2
Installing Your Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
"! CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
"!!WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-6. Explosion-Proof XIR Remote Sensor Model . . . . . . . . . . 1-3
Installing the Ultima XA Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installing the Ultima XE Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-7. Ultima XE and XIR Mounting Strap Mounting Method . . . 1-4
Installing the Ultima XIR Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
"! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-8. Ultima XIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrical Connections for Ultima X Gas Monitors . . . . . . . . . . . . . . . . . . . 1-6
"! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Wiring for all Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
For Milliamp Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Table 1-1. Power Signal Cable Length and Wire Size (Toxic Gas or
Oxygen) Sensor, 4-20 mA Signal Output (Two Wire Sensor) 1-7
Table 1-2. Ultima XE and XA Maximum Cable Length and 4-20 mA
Signal Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Typical Ultima X Series Gas Monitor Wiring . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table 1-3.Cable Length and Wire Size (Power Supply 24 VDC) (Toxic
Gas or Oxygen) Sensor, 4-20 mA Signal Output (Three Wire
Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table of Contents
TOC-1

Table 1-4. Ultima XIR Maximum Cable Length
and 4-20 mA Signal Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-9. Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Figure 1-10. General-Purpose Two-Wire Operation . . . . . . . . . . . . . 1-10
Figure 1-11. General-Purpose Three-Wire 4 to 20 mA Operation . . . 1-10
Figure 1-12. Explosion-Proof Two-Wire Operation . . . . . . . . . . . . . . 1-11
Figure 1-13. Explosion-Proof Three-Wire 4 to 20 mA Operation . . . . 1-11
Installing the Ultima X Remote Sensor Module . . . . . . . . . . . . . . . . . . . 1-12
Electrical Connections for the Ultima X Series Remote Sensor Module 1-12
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
"!CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Table 1-5. Remote Module Wiring and Placement* . . . . . . . . . . . . . . 1-13
Table 1-6. Remote Sensor Wiring Cable . . . . . . . . . . . . . . . . . . . . . . 1-13
Table 1-7. Low Temperature Wiring Cable . . . . . . . . . . . . . . . . . . . . . 1-13
At the Ultima X Series Remote Sensor Location: . . . . . . . . . . . . . . . . . . 1-13
Chapter 2
Start-up and Calibration . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1. LCD Gas Concentration Display . . . . . . . . . . . . . . . . . . . 2-1
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Table 2-1. Instrument Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Calibration Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Non-combustible Chemicals that Reduce Catalytic Sensor Sensitivity . . 2-4
Figure 2-2. Ultima Calibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Ultima Calibrator . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . 2-5
Ultima Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Note on Resetting Latched Alarms with Controller or Calibrator . . . . . . . 2-5
Ultima X Series Gas Monitor Calibration Output Signal . . . . . . . . . . . . . . 2-5
Figure 2-3. Ultima Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Calibration Kit . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2-6
Ultima X Series Gas Monitor Calibration Procedure . . . . . . . . . . . . . . .. . 2-6
INITIAL Calibration . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 2-6
Table of Contents
TOC-2

Regular Calibration . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Zeroing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-4. Apply Zero Gas Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-5. Apply SPAN Gas Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-6. Calibration End Display . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
XIR Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Calibration Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Chapter 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-1. Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-2. Sensor Response to Interferants . . . . . . . . . . . . . . . . . . . . . 3-5
Chapter 4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Ultima XIR Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Replacing an Ultima XE or Ultima XA Sensor . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-1. "Change Sensor" Scrolls Across the Display . . . . . . . . . . 4-2
"! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
"! CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 4-2. Sensor Assembly and Sensor Guard
for General Purpose Model . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Table 4-1. Operational Display Messages . . . . . . . . . . . . . . . . . . . . . . 4-4
Table 4-2. Configuration Display Messages . . . . . . . . . . . . . . . . . . . . . 4-5
Table 4-3. Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Table 4-4. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Table of Contents
TOC-3

Appendix A
Internal Relay Option . . . . . . . . . . . . . . . . . . . . . . . A-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Unpacking, Mounting and Wiring the Ultima X Series Gas Monitor with
Internal Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Figure A-1. Dual Module General-Purpose Ultima X Series Wiring . . A-2
Figure A-2. Dual Module Explosion-Proof Ultima X Series Wiring . . . A-3
Figure A-3. Single Module General-Purpose Ultima X Series Wiring A-4
Figure A-4. Single Module Explosion-Proof Ultima X Series Wiring . A-4
TABLE A-1. Power Cable Distances
for the Ultima X Series Gas Monitor w
ith Internal Relays (4-20 mA Model) . . . . . . . . . . . . . . . . . . . A-5
Ultima X Series Gas Monitor Internal Relays . . . . . . . . . . . . . . . . . . . . . . A-6
Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Table A-2. Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Fault Relay or Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Figure A-5. Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Optional RESET Push-button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
RESET Button Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Optional Push-button Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Table A-3. Push-button Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Relay Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
"! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Figure A-6. Relay Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . A-11
Table of Contents
TOC-4

Chapter 1
Installation
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.
Identifying Your Unit
•The Ultima XA Gas Monitor is housed
in a rugged, plastic general-purpose
enclosure (FIGURE 1-1).
•The Ultima XE Gas Monitor is housed
in a 316 stainless steel explosion-proof
enclosure (FIGURE 1-2).
•The Ultima XIR Gas Monitor is housed
in a 316 stainless steel explosion-proof
enclosure (FIGURE 1-3).
•The Remote Sensor Models are shown
in FIGURES 1-4, 1-5 and 1-6. If your
unit contains internal relays, see
Appendix A.
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 sensor 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 (2 or 3 wire, 4 to 20 mA)
•Any options such as internal relays
and/or LEDs.
Figure 1-1.
General-Purpose Ultima
XA Monitor
Figure 1-2. Explosion-Proof
Ultima XE Monitor
Figure 1-3. Explosion-Proof
Ultima XIR Monitor
Chapter 1, Installation
1-1

Figure 1-4.
General-Purpose XA Remote Sensor Model
Figure 1-5.
Explosion-Proof XE Remote Sensor Model
Chapter 1, Installation
1-2

Installing Your Gas Monitor
NOTE: Reference installation outline drawings listed in
Chapter 3, "Specifications".
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 expected. 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. Install the unit so that the front
display of the unit is not blocked or hidden from view.
"! CAUTION
Mount the Ultima XE or XA Gas Monitor or remote sensing module
with the sensor inlet fitting (FIGURE 1-1, 1-2, 1-4 or 1-5) pointed
downwards; otherwise, the inlet may become clogged with
particulate matter or liquids.
Mount the Ultima XIR Gas Monitor or Remote Sensing Module with
thesensorinletfittingextendedhorizontallyfromthemainenclosure
(FIGURE 1-3 and 1-6) 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 notdeposited on thesensor inlet fitting. Such paint deposits
would interfere with the diffusion process, whereby a sample of
the monitored atmosphere 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.
"!!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 flammable mixture of combustible gas and air
may become present; otherwise, an explosion may occur. If such
a location must be monitored, use an explosion-proof gas monitor.
Figure 1-6.
Explosion-Proof XIR Remote Sensor Model
Chapter 1, Installation
1-3

Installing the Ultima XA Gas Monitor
Remove lid and drill enclosure for power, signal and optional
relay cable entry. Use one of the following methods to mount the
general-purpose Ultima XA Gas Monitor/Less Sensor or the
Ultima XA Gas Monitor.
•Using customer-installed wiring holes, install the Ultima XA Gas
Monitor to the end of rigid conduit.
•Use mounting holes in the corners of the Ultima XA enclosure
to mount directly to a wall.
Installing the Ultima XE Gas Monitor
•Use the optional mounting kit (P/N 10047561) that can be
attached to the rear holes of the Ultima XE Gas Monitor
(FIGURE 1-7).
•The Ultima XE Gas Monitor main enclosure can be rotated 360o
and mounted to ensure easy access to any of the four
entryways. The electronics assembly can be installed in any of
the four self-aligning positions to ensure the display is properly
oriented.
•The Ultima XE Gas Monitor sensor is not shipped attached to
the main enclosure. Mount the sensor module with the
applicable conduit only. Ensure the sensor wiring harness is
through the entry and the sensor is pointing downward. Tighten
with a strap wrench.
Figure 1-7.
Ultima XE and XIR Mounting Strap Mounting Method
Chapter 1, Installation
1-4

Installing the Ultima XIR Gas Monitor
"! WARNING
The Ultima XIR Combustible Gas Monitor contains no user- or
field-serviceable parts and must bereturned to the factory for repair.
Any attempt to open the monitor will damage the unit and void
the warranty.
•Use the optional mounting strap (P/N 697281) that can be attached
to the rear holes of the Ultima XE Gas Monitor (FIGURE 1-7).
•The Ultima XE Gas Monitor main enclosure can be rotated 360o
and mounted to ensure easy access to any of the four entryways.
The electronics assembly can be installed in any of the four
self-aligning positions to ensure the display is properly oriented.
"CAUTION
Under no circumstances should a wrench or pry-bar be applied
to the two legs that support the unit’s reflectors during installation
or removal of the sensor (FIGURE 1-8). Applying force to the legs
can permanently damage the monitor.
It is recommended that the monitor’s environmental guard be
installed on the unit at all times. If the monitor is to be operated
without the guard, frequent checks should be made to ensure
particulate or liquid matter has not collected on the windows.
With its environmental guard installed, the XIR Gas Monitor’s
response time to a step change in gas concentration exceeds the
limits specified by the Canadian Standards Association (CSA). The
XIR monitor must be operated with the environmental guard
removed to maintain CSA performance certification. note that the
environmental guard is required tocheck or adjusttheXIR monitor’s
zero and span.
Figure 1-8.
Ultima XIR
Chapter 1, Installation
1-5

Electrical Connections for Ultima X Gas Monitors
"! WARNING
Before wiring the Ultima X Series Gas Monitors,disconnect powersource
supplying the monitor; otherwise, electrical shock could occur.
For Ultima XE and XIR installations, the internal grounding terminal
must be used for equipment grounding. The external grounding
terminal is only to be used as a supplemental bonding connection
where local authorities permit or require such a connection.
NOTE: For Ultima X Series units with internal relays, see Appendix A.
This assembly is marked to identify power, ground and signal
connections.
•A two-wire connection is possible for certain:
•Toxic Gas models with 4 to 20 mA output
•Oxygen models with 4 to 20 mA output
•A three-wire connection is required for all:
•Combustible Gas models
•Toxic and Oxygen Models with 4 to 20 mA output, that are
to be operated in connection with accessory functions
(relays, etc.).
Wiring for all Models
Install wiring in accordance with the electrical code of the country
in use and UL 61010-A1 or CSA C22.2 No. 1010.1, as
applicable. In these installations, twisted-pair, instrument quality
cable is recommended. Shielded cable is recommended for cable
runs where interferences from radio frequency interference (RFI),
electromagnetic interference (EMI) or other noise sources exist
(such as motors, welding equipment, heaters, etc.).
NOTE: See Installation Outline Drawings for wiring details as
specified in Chapter 3, "Specifications".
Conduit may also be needed in areas where large amounts of
electrical noise is expected.
Use caution when selecting a cable size. The following tables
express the maximum cable length when only using the Ultima X
Series Gas Monitors. Ultima X Series options may take additional
power which requires a heavier cable or a short cable run.
When selecting cable size, consider future needs (i.e., addition of
sensors and/or options available with the Ultima X Series
Monitors). See Chapter 3, "Specifications" for proper input voltage.
Ensure that water and dirt are not able to enter the unit via the
wire or conduit. If the unit is installed in a location known to be
Chapter 1, Installation
1-6

wet or damp, it is good practice to loop or bend the entry into
the unit that prevents water incursion.
For Milliamp Output
The Ultima X Series Gas Monitors may be connected to any
device capable of accepting 4 to 20 mA analog signals such as:
•Model 5000 unit (with 4 to 20 mA inputs)
•Quad Gas Controller
•Programmable controllers
•DCS’s, etc.
An external power supply is required. (For power requirements,
see Chapter 3, "Specifications".) All connections should be made
by following appropriate wire code procedures.
•See TABLES 1-1 through 1-4 for typical cable length and wire
size for installation.
"WARNING
When using any of the the Ultima X Series accessories (such as
relays) with the 4 to 20 mA output Ultima X Series Gas Monitor,
a three-wire connection must be used. Failure to use a three-wire
connection could damage the electronics within the Ultima X Series
Gas Monitor which can result in serious personal injury or death.
Be sure toinstallyourUltimaX Series GasMonitoraccording to National
Electrical and local procedural codes. Failure to do so can result in
an unsafe condition.
Table 1-1. Power Signal Cable Length and Wire Size (Toxic Gas
or Oxygen) Sensor, 4-20 mA Signal Output (Two Wire Sensor)
WIRE
SIZE MAXIMUM CABLE
LENGTH IN FEET
AT 24 VDC MAXIMUM LOAD
RESISTANCE MAXIMUM CABLE
LENGTH IN FEET
AT 12 VDC
MAXIMUM
LOAD
RESISTANCE
22
AWG 7,000 600 Ohms 4,000 100 Ohms
Table 1-2. Ultima XE and XA Maximum Cable Length and
4-20 mA Signal Load
POWER SUPPLY 24 VOLTS 12 VOLTS
CONFIGURATION NO RELAYS RELAYS
INSTALLED NO RELAYS RELAYS
INSTALLED
22 AWG CABLE 1000 FEET 800 FEET - - - - - -
18 AWG CABLE 2500 FEET 2100 FEET 900 FEET 640 FEET
16 AWG CABLE 4200 FEET 3000 FEET 1400 FEET 900 FEET
12 AWG CABLE 10,000 FEET 7700 FEET 3600 FEET 2200 FEET
MAXIMUM LOAD ON
4 - 20 mA SIGNAL 600 OHMS 300 OHMS
Chapter 1, Installation
1-7

NOTE: TABLES 1-1 through 1-4 do not apply to Ultima X
Series Gas Monitors with Internal Relays. If Internal
Relays exist, see Appendix A.
Typical Ultima X Series Gas Monitor Wiring
•Two-wire 4 to 20 mA Ultima X Series Monitors operate in the
current loop mode (FIGURE 1-10 for general-purpose)
(FIGURE 1-12 for explosion-proof)
•Three-wire Ultima X Series Monitors operate in the current
source mode (see FIGURE 1-11 for general-purpose)
(FIGURE 1-13 for explosion-proof).
1. Identify the main pc board as a two-wire or a three-wire unit:
•For XA Gas Monitors
while looking at the main pc board, locate the identifying
label on the underside of the lid:
•A-ULTX-PCB-A-Bis a two-wire unit
•A-ULTX-PCB-A-Eis a three-wire unit
Table 1-3.
Cable Length and Wire Size (Power Supply 24 VDC) (Toxic Gas
or Oxygen) Sensor, 4-20 mA Signal Output (Three Wire Sensor)
WIRE SIZE MAXIMUM CABLE LENGTH IN FEET MAXIMUM LOAD RESISTANCE
22 AWG 12,000 600 Ohms
Table 1-4. Ultima XIR Maximum Cable Length
and 4-20 mA Signal Load
POWER SUPPLY 24 VOLTS 12 VOLTS
CONFIGURATION NO RELAYS RELAYS
INSTALLED NO RELAYS RELAYS INSTALLED
18 AWG CABLE 2000 FEET 1500 FEET 300 FEET 250 FEET
16 AWG CABLE 3500 FEET 2500 FEET 500 FEET 400 FEET
12 AWG CABLE 5000 FEET 4000 FEET 900 FEET 600 FEET
MAXIMUM LOAD
ON 4 - 20 mA
SIGNAL 600 OHMS 300 OHMS
Chapter 1, Installation
1-8

•For XE and XIR Gas Monitors
locate the identifying label on the side of the plastic
shroud for the main pc board:
•A-ULTX-PCB-E-Bis a two-wire unit
•A-ULTX-PCB-E-Eis a three-wire unit
2. Connect 7 to 30 VDC power lead to J8-1 (see FIGURE 1-9).
3. Connect J8-2 to 4 to 20 mA input on remote system.
4. For three-wire operation, connect the signal ground to J8-3
(for two-wire operation, there is no connection to J8-3).
5. Connect the sensor module to labeled connector J-1 on the
main pc board.
6. Wire for optional relays and/or acknowledge push-button
(see Appendix A).
7. Assemble lid on enclosure.
Figure 1-9.
Circuit Board
Chapter 1, Installation
1-9

Figure 1-10.
General-Purpose Two-Wire Operation
Figure 1-11.
General-Purpose Three-Wire 4 to 20 mA Operation
Chapter 1, Installation
1-10

Figure 1-12.
Explosion-Proof Two-Wire Operation
Figure 1-13.
Explosion-Proof Three-Wire 4 to 20 mA Operation
Chapter 1, Installation
1-11

Installing the Ultima X Remote Sensor Module
The Remote Sensor Module is used with the Ultima X Gas
Monitor/less sensor.
The Remote Sensor Module can be mounted in a manner similar
to the gas monitor installation in the preceding procedure and at
a maximum distance outlined in TABLE 1-5.
Permanently connect 1/4" ID tubing to the post on the windguard.
Route this tubing to the Ultima X Gas Monitor, ensuring that
there are no kinks, leaks or other obstructions. Secure this tubing
near the monitor; it is used to deliver check gas to the sensor
module during calibration.
Electrical Connections for the Ultima X Series
Remote Sensor Module
"!WARNING
Before wiring the Ultima X Series Remote Sensor Module,
disconnect the power source feeding the Remote Sensor Module
and the Ultima X Series Gas Monitor/Less Sensor; otherwise,
electrical shock could occur.
"!CAUTION
When installing an Ultima X Series Remote Sensor Module with
its mating Ultima XSeries Gas Monitor/Less Sensor, follow National
Electrical and local procedural Codes; failure to do so can result
in an unsafe condition.
Five conductors are required for the Ultima XE and Ultima XA
Remote Sensor Modules. Four conductors are required for the
Ultima XIR Remote Sensor Module. The Ultima X Series Monitor
has a five-wire terminal to accommodate up to #16 AWG
conductors.
Some installations require metal pipe or metallic conduit. In these
cases, separate conductors or unshielded cable may be used.
For open wiring, shielded wire or cable should be used to
minimize the possibility of noise interference and contact with
other voltages. Selection of this shielded cable must comply with
local requirements.
Chapter 1, Installation
1-12