MSA Ultima User manual

Ultima®Gas Monitor
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.
© MINE SAFETY APPLIANCES COMPANY 2004 - All Rights Reserved
Manufactured by
MSA INSTRUMENT DIVISION
P.O. Box 427, Pittsburgh, Pennsylvania 15230
(L) Rev 12 813161

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
"!WARNINGS
1. The Ultima 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. To prevent ignition of a hazardous atmosphere, the cover of
an explosion-proof model of the Ultima Gas Monitor must be
kept tightly closed when power is applied. Before removing
the cover for maintenance or calibration, ensure the
surrounding atmosphere is and remains free of toxic or
combustible gases until the cover is closed.
3. The Ultima 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.
4. 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.
5. 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 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.
6. 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 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 be present; otherwise, an

explosion may occur. If such a location must be monitored,
use an explosion-proof Ultima Gas Monitor model.
7. The Ultima IR 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 should never be
used to monitor for hydrogen gas.
Failure to follow the above can result in serious personal
injury or death.
"CAUTIONS
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 Gas Monitor may be exposed to such materials,
calibration should be performed frequently to ensure that
operation is dependable and display indications are accurate.
2. The Ultima 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 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 Monitor is to check it with a known
concentration of the gas for which it has been calibrated.
Consequently, calibration checks should be included as part
of the routine inspection of the system.
4. Protect the Ultima 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
Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Unpacking Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-1. Toxic Gas or Oxygen General-Purpose Models . . . . . . . 1-1
Identifying Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1-2. Remote Sensor Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1-3. Combustible Gas Explosion-proof Model . . . . . . . . . . . . 1-3
Figure 1-4. Toxic Gas or Oxygen Explosion-proof Model . . . . . . . . . 1-3
Hazardous Area Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-5. Shipping Carton Label Identifying Sensor Type . . . . . . . 1-4
Figure 1-6. Sensor Label Identifying Sensor Type . . . . . . . . . . . . . . . 1-5
Figure 1-7. Label Indicating Enclosure Classification . . . . . . . . . . . . 1-5
Intrinsically Safe Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-8. Cable Grip for General-Purpose or Intrinsically Safe
Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Mounting Your Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
"! CAUTION . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . 1-7
"!!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Mounting Guidelines for the Explosion-Proof Ultima Gas Monitor . . . . . . 1-7
Mounting Guidelines for the General-Purpose Gas Monitor . . . . . . . . . . . 1-8
Mounting Guidelines for the Ultima Gas Monitor/Less Sensor . . . . . . . . . 1-8
Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Three Mounting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Mounting the Ultima Remote Sensor Module . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-9. NPT Thread Mounting Method . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-10. Mounting Strap Mounting Method . . . . . . . . . . . . . . . . . . 1-9
Figure 1-11. Mining Mounting Method . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Electrical Connections for Ultima Gas Monitors . . . . . . . . . . . . . . . . . . . 1-10
"! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Figure 1-12. Ultima Remote Sensor Module . . . . . . . . . . . . . . . . . . . 1-10
Table of Contents
TOC-1

Figure 1-13. Remote Sensor Mounting Method . . . . . . . . . . . . . . . . 1-10
Figure 1-14. Two-Wire Harness Assembly . . . . . . . . . . . . . . . . . . . . 1-11
Figure 1-15. Three-Wire Harness Assembly . . . . . . . . . . . . . . . . . . . 1-11
Figure 1-16. Bottom Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Wiring for all Models (except digital output models) . . . . . . . . . . . . . . . . 1-12
For Frequency Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
For Multiplex Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
For Milliamp Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Table 1-1. Cable Length and Wire Size,
Toxic Gas or Oxygen Sensor, Frequency Signal Output . . . 1-13
Table 1-2. Cable Length and Wire Size,
Combustible Gas Sensor, Frequency Signal Output . . . . . 1-13
Table 1-3. Cable Length and Wire Size,IR Combustible Sensor . . . . 1-13
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Table 1-4. Cable Length and Wire Size (Toxic Gas or Oxygen) Sensor,
4-20 mASignal Output (Two Wire Sensor) . . . . . . . . . . . . . 1-14
Table 1-5. Cable Length and Wire Size Combustible Gas Sensor,
4-20 mASignal Output (Three Wire Sensor) . . . . . . . . . . . 1-14
Typical Wiring of the Ultima Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Table 1-6. Cable Length and Wire Size (Power Supply 24 VDC) (Toxic
Gas or Oxygen) Sensor, 4-20 mASignal Output (Three Wire
Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Table 1-7. Cable Length and Wire Size IR Combustible Gas Sensor,
4-20 mASignal Output (Three Wire Sensor) . . . . . . . . . . . 1-15
Figure 1-17. Two-Wire Monitor Operation . . . . . . . . . . . . . . . . . . . . . 1-15
Electrical Connections for the Ultima Remote Sensor Module . . . . . . . . 1-16
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Figure 1-18. Three-Wire 4 to 20 mA Monitor Operation . . . . . . . . . . 1-16
Figure 1-19. Three-Wire Frequency or MUX Monitor Operation . . . . 1-16
"!CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
For Catalytic Type Combustible Models . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Table 1-8. Wire Gauge Vs. Distance . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Table 1-9. Remote Sensor Wiring Cable . . . . . . . . . . . . . . . . . . . . . . 1-18
Figure 1-20. Combustible Catalytic Ultima Gas Monitor . . . . . . . . . . 1-18
"! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Table of Contents
TOC-2

Figure 1-21. Accessing the Wiring Terminal Block . . . . . . . . . . . . . . 1-19
"! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Figure 1-22. Sensor Wiring Connections . . . . . . . . . . . . . . . . . . . . . . 1-20
"! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Figure 1-23. Catalytic Combustible Remote Sensor . . . . . . . . . . . . . 1-21
"! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
For Oxygen Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Figure 1-24. Oxygen and Toxic Ultima Gas Monitor Less Sensor . . . 1-22
"! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Figure 1-25. Oxygen Remote Sensor Cable . . . . . . . . . . . . . . . . . . . 1-23
"! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
For Toxic Gas and IR Combustible Models . . . . . . . . . . . . . . . . . . . . . . . 1-24
Figure 1-26. IR Combustible, Oxygen, and Toxic Remote Sensor . . 1-24
"! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Figure 1-27. Toxic Gas Remote Sensor Cable . . . . . . . . . . . . . . . . . 1-25
Figure 1-28. IR Combustible Remote Sensor Cable . . . . . . . . . . . . . 1-25
"! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Chapter 2
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1. LCD Gas Concentration Display . . . . . . . . . . . . . . . . . . . 2-1
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-2. Calibration Flag Display . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Non-combustible Chemicals that Reduce Catalytic Sensor Sensitivity . . . 2-4
Ultima Gas Monitor Calibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-3. Ultima Gas Monitor Calibrator . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-4. Ultima Gas Monitor Controller . . . . . . . . . . . . . . . . . . . . . 2-4
Ultima Gas Monitor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Note on Resetting Latched Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Ultima Gas Monitor Calibration Output Signal . . . . . . . . . . . . . . . . . . . . . . 2-5
Table of Contents
TOC-3

Table 2-1. Sensor Response to Interferants . . . . . . . . . . . . . . . . . . . . . 2-6
Chapter 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-1. Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Chapter 4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Replacing the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 4-1
Hydrogen Cyanide and Hydrogen Chloride Sensors . . . . . . . . . . . . . . . . 4-1
Figure 4-1. Change Sensor Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
"! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
"! CAUTION. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 4-2
"! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-2. Cap for Catalytic Combustible Gas
Explosion-proof Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 4-3. Cap for Toxic Gas or Oxygen General-purpose Model . 4-3
Figure 4-4. Cap for Toxic Gas, Oxygen, or Combustible IR
Explosion-proof Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-5. Catalytic Combustible Three-Pin Connector . . . . . . . . . . 4-4
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-6. CAL FAULT Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Table 4-1. Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 4-9
Table 4-2. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Appendix A
Optional Ultima Duct Mount Kit . . . . . . . . . . . . . . . A-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Figure A-1. Ultima Duct Mount Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table of Contents
TOC-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Mounting the Single Module Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Figure A-2. Duct Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table A-1. Single module Duct Mount Kit Parts List . . . . . . . . . . . . . . A-4
"!WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Figure A-3. Ultima Gas Monitor Mounting Bracket . . . . . . . . . . . . . . A-4
Figure A-4. Ultima Gas Monitor Spacers . . . . . . . . . . . . . . . . . . . . . A-5
Figure A-5. Ultima Gas Monitor Clamp . . . . . . . . . . . . . . . . . . . . . . . A-5
Figure A-6. Ultima Gas Monitor Enclosure Gasket . . . . . . . . . . . . . . A-5
Figure A-7. Ultima Gas Monitor Plate . . . . . . . . . . . . . . . . . . . . . . . . A-6
Figure A-8. Duct Mount Kit Base Plate . . . . . . . . . . . . . . . . . . . . . . . A-6
Figure A-9. Toxic or Oxygen Ultima Gas Monitor Termination Board A-7
Figure A-10. Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Figure A-11. Duct Mount Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Mounting the Dual module Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Table A-2. Dual module Duct Mount Kit Parts List . . . . . . . . . . . . . . . A-10
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Figure A-12. Remote Sensor Spacers . . . . . . . . . . . . . . . . . . . . . . . A-11
Figure A-13. Remote Sensor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Figure A-14. Remote Sensor Base Plate . . . . . . . . . . . . . . . . . . . . . A-12
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Figure A-15. Duct Mount and Sensor . . . . . . . . . . . . . . . . . . . . . . . . A-14
Appendix B
Optional Ultima Power Supply . . . . . . . . . . . . . . . . B-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Wiring the Ultima Power Supply Module
Using the Internal Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Figure B-1. Ultima Power Supply Module . . . . . . . . . . . . . . . . . . . . . B-2
Table of Contents
TOC-5

Figure B-2. Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Appendix C
Internal Relay Option . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Figure C-1. Dual module Ultima Wiring Harness . . . . . . . . . . . . . . . . C-2
Figure C-2. Single module Ultima Wiring Harness . . . . . . . . . . . . . . . C-2
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Unpacking, Mounting and Wiring the Ultima Gas Monitor with Internal
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Table C-1. Power Cable Distances for the Ultima Gas Monitor
with Internal Relays (4-20 mAor Frequency Output Models) C-4
Ultima Gas Monitor Internal Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Table C-2. Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Fault Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Optional RESET Push-button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
RESET Button Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . C-6
Table C-3. RESET Push-button Vendors . . . . . . . . . . . . . . . . . . . . . . . C-7
Relay Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Figure C-3. Relay Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Table C-4. Wire Color and Associated Relay . . . . . . . . . . . . . . . . . . . . C-8
If the Wiring Harness is Not Used: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . C-8
Figure C-4. Relay Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . C-9
"! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Table of Contents
TOC-6

Chapter 1
Set-up
Unpacking Your Unit
Several cartons may arrive with your order; locate the carton(s)
marked as the Ultima Gas Monitor or Ultima Gas Monitor/Less
Sensor. Upon receipt, ensure that your package contains:
•Ultima Gas Monitor (FIGURE 1-1)
•Ultima Gas Monitor Instruction Manual (P/N 813161). If
your unit is an Ultima Gas Monitor with Digital Output,
there will be an additional manual (P/N 710471)
•Ultima Remote Sensor Module, if equipped as a dual
module model (FIGURE 1-2)
General Description
The Ultima 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:
Figure 1-1.
Toxic Gas or Oxygen General-Purpose Models
Chapter 1, Set-up
1-1

The unit is shipped ready for installation via an external wiring
harness. This harness is to connect to power and any output
signals, eliminating the need to open the enclosure for installation
or operation.
Identifying Your Unit
All models of the Ultima Gas Monitor, all housed in rugged,
aluminum enclosures are designed to meet NEMA 4X. These
versions with milliamp or frequency output can be installed as
Intrinsically Safe for Classification I, Groups B, C and D, Division,
1, Hazardous Locations; the catalytic combustible gas version can
be installed as Intrinsically Safe for Classification I, Groups C and
D only. The combustible IR models are not installable as
intrinsically safe. These approvals also cover areas classified as
Class I, Division 2 and are noted on the unit label.
Check the identifying label (see FIGURE 1-7) to be sure the
version you are installing is rated as Intrinsically Safe when
installed according to the drawing specified on the label.
IF YOUR UNIT IS: REFER TO:
To be used with the optional Ultima Duct Mount Kit Appendix A
Powered with the Optional Power Supply Module Appendix B
contains internal relay Appendix C
Figure 1-2.
Remote Sensor Model
Chapter 1, Set-up
1-2

•Two models are available in GENERAL-PURPOSE housings
(FIGURE 1-1):
•Toxic Gases
•Oxygen
•Three models are available in EXPLOSION-PROOF housings
certified for Classification I, Groups B, C and D, Division 1,
Hazardous Locations.
•Combustible Gas (FIGURE 1-3):
•Certain Toxic Gases (FIGURE 1-4):
•Oxygen (FIGURE 1-4):
Figure 1-3.
Combustible Gas Explosion-proof Model
Figure 1-4.
Toxic Gas or Oxygen Explosion-proof Model
Chapter 1, Set-up
1-3

•All five models are available as Remote Sensor models
(FIGURE 1-2).
To determine your sensor type and options, check the shipping
carton (FIGURE 1-5) and sensor ID label located on the sensor
cover or on the body of the module enclosure (FIGURE 1-6).
Items which are checked are included in the carton.
This label identifies:
•Sensor supplied (Ultima Gas Monitor, Ultima Gas Monitor Less
Sensor, or Ultima Remote Sensing Module)
•Type of gas (combustible gas, toxic gas or oxygen)
•Range [% LEL, PPM (parts per million), or %]
•Output (frequency, multiplex, digital, 2 or 3 wire, 4 to 20 mA)
NOTE: The Ultima Digital Output Gas Monitor has its own
manual; consult the Ultima Digital Output Gas
Monitor Manual (P/N 710471) for more details.
•Any options such as internal relays
Hazardous Area Rating
IMPORTANT NOTE: Some models of the Ultima Gas Monitor
can be used in hazardous atmospheres. These models are in
explosion-proof enclosures and must be installed according
Figure 1-5.
Shipping Carton Label Identifying Sensor Type
Chapter 1, Set-up
1-4

to the National Electric Code. Some Ultima Gas Monitor
enclosures are rated for Class I, Division 1, Groups B, C and
D areas, while others can only be used in Groups C and D
areas. The larger, metal Approval Label on the Ultima Gas
Monitor (FIGURE 1-7) will indicate the rating of your
particular model and if it is approved for use in hazardous
areas. The second approval label indicates the unit is also
classified for Class I, Division 2 operation.
The Ultima Gas Monitor may be equipped with thread protectors;
all thread protectors must be removed before installation. All
units have cable harnesses. The unit must not be carried by
these harnesses; otherwise, unit will be damaged.
If the unit is to be mounted in a general-purpose or intrinsically
safe area, a cable grip can be used (FIGURE 1-8). A cable grip
cannot be used when the unit is installed in an area classified as
explosion-proof. Follow applicable wiring and installation codes.
Figure 1-6.
Sensor Label Identifying Sensor Type
Figure 1-7.
Label Indicating Enclosure Classification
Chapter 1, Set-up
1-5

Intrinsically Safe Rating
Some models of the Ultima Gas Monitor can be used in
hazardous atmospheres as intrinsically safe and must be installed
according to the National Electric Code and the appropriate
control drawings. Intrinsically safe installations of the Ultima Gas
Monitor require the use of electrical barriers which are available
from MSA. The proper use of these electrical barriers are outlined
on the appropriate control drawings. Select the control drawing
(available from MSA (1-800-MSA-INST) applicable to your unit:
ULTIMA GAS MONITOR CONTROL DRAWING
Toxic or oxygen models, Milliamp or Frequency output DSK3098-11
Combustible catalytic type model, Milliamp or Frequency output DSK3098-13
"WARNING
Do not use an intrinsically safe Ultima Gas Monitor with its
electrical barriers beyond its area classification ratings;
otherwise, an explosion may occur.
Refer to the larger, metal Approval Label located on the main
enclosure of the Ultima Gas Monitor (FIGURE 1-7) for rating
information. Some Ultima Gas Monitor enclosures are rated for
Class I, Division 1, Groups B, C and D areas, while others can
only be used in Groups C and D areas.
All intrinsically safe Ultima Gas Monitors operate at 12 volts only.
The Multiplex and the Digital Output models are not capable of
operating in an intrinsically safe manner with any type of
electrical barrier.
If options such as internal relays are installed or accessories
such as the Remote Relay Module or the Autocal Module are
used, the Ultima Gas Monitor will not be rated as Intrinsically
Safe. Refer to the metal Approval Label (FIGURE 1-7).
Figure 1-8.
Cable Grip for General-Purpose or Intrinsically Safe Installations
Chapter 1, Set-up
1-6

Mounting Your Gas Monitor
Generally, the unit or the remote sensing module should be
mounted close to the area where a leak is likely to occur or
where the gas is expected. The Ultima Gas Monitors or the
remote sensing module should be installed at a high level
(ceiling) or low level (floor), depending on the density of the gas
most likely to be found. Mount the unit so that the front display of
the unit is not blocked or hidden from view.
"! CAUTION
Mount the Ultima Gas Monitor or the remote sensing module
with its sensor inlet fitting (FIGURE 1-1 or 1-2) pointed
downwards; otherwise, the inlet may become clogged with
particulate matter or liquids. Do not paint the Ultima Gas
Monitor. If painting is done in an area where a sensor is
located, exercise CAUTION to ensure paint is not deposited
on the sensorinlet fitting. Suchpaintdeposits 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 Gas Monitor from extreme vibration. Do not
mount the 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 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 be
present; otherwise, an explosion may occur. If such a
location must be monitored, use an explosion-proof Ultima
Gas Monitor model.
Mounting Guidelines for the Explosion-Proof Ultima
Gas Monitor
An explosion-proof model of the Ultima Gas Monitor can be
mounted in Class I, Groups B, C and D, Division 1, Hazardous
Locations defined by Article 500 of the National Electrical Code
(NEC). The term "explosion-proof" is used as defined by the
NEC, Article 100:
“Explosion-Proof” Apparatus: Apparatus enclosed in a case
that is capable of withstanding an explosion of a specified
Chapter 1, Set-up
1-7

gas or vapor which may occur within it and of preventing
the ignition of a specified gas or vapor within, and which
operates at such an external temperature that a surrounding
flammable atmosphere will not be ignited thereby."
Mounting Guidelines for the General-Purpose Gas Monitor
The general-purpose gas model is designed to meet NEMA 4X
requirements, suitable for many damp, wet and/or outdoor locations.
Mounting Guidelines for the Ultima Gas Monitor/Less
Sensor
The Ultima Gas Monitor/Less Sensor is used with the Ultima Remote
Sensor Module. It is mounted at a convenient, accessible location while
the Remote Sensor Module is mounted where the gas is expected.
Mounting the Unit
Use one of the following three methods to mount the Ultima Gas
Monitor/Less Sensor or the Ultima Gas Monitor.
Three Mounting Methods
•Via the 3/4-inch NPT
threads: install the Ultima
Gas Monitor to the end of a
rigid conduit (FIGURE 1-9).
•Via the optional mounting
strap (P/N 697281) that can
be attached to the rear holes
of the Ultima Gas Monitor
(FIGURE 1-10)
•For mining applications, via
the optional hanger bracket
(P/N 814513) that can be
attached to the rear holes of
the Ultima Gas Monitor
(FIGURE 1-11).
Mounting the Ultima
Remote Sensor Module
The Ultima Remote Sensor Module is mounted where the gas is
expected to exist. It is mounted with the sensor pointing
downward via the 3/4" NPT threads. These threads are located
on the end of the module, opposite the sensor (FIGURE 1-12). It
can also be mounted with the mounting strap (P/N 655700); see
Figure 1-9.
NPT Thread Mounting Method
Chapter 1, Set-up
1-8

Figure 1-10.
Mounting Strap Mounting Method
Figure 1-11.
Mining Mounting Method
Chapter 1, Set-up
1-9

FIGURE 1-13. The sensor module wiring is routed
to the Ultima Gas Monitor which does not contain
a sensor.
Permanently connect 1/4" OD tubing to the center
post of the sensor inlet. Route this tubing to the
Ultima 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
Ultima Gas Monitors
"! WARNING
Before wiring the Ultima Gas Monitor, disconnect
power source supplying the monitor; otherwise,
electrical shock could occur.
Before removing the cover of an explosion-proof
Ultima Gas Monitor, verify the surrounding area does
not contain a flammable mixture of combustible gas
and air since a source of ignition is exposed;
otherwise, an explosion may occur if a metal object
contacts the circuitry and produces sparks.
NOTE: For Ultima with Digital Output Gas
Monitors, see manual (P/N 710471) for
wiring instructions.
NOTE: For Ultima units with
internal relays,
see Appendix C.
There is no need to open the
enclosure during a typical
installation because the Ultima
Monitor design eliminates:
•Internal jumpers
(except IR versions)
•Potentiometers
•Dip switches or other
types of adjustments.
All electrical connections to the
Ultima Monitor can be made via
the factory- installed wiring
harness (FIGURES 1-14 and
Figure 1-12.
Ultima Remote
Sensor Module
Figure 1-13.
Remote Sensor Mounting Method
Chapter 1, Set-up
1-10