Honeywell XNX User guide

XNXTM Universal Transmitter

Safety Manual

Revision 2

• Table of Contents

• SIL 2 Certiﬁcates

• Overview

• Safety Parameters

• Fault Diagnostic Time Interval

• Proof Test

• Proof Testing Procedure

XNX Universal Transmitter

Table of Contents

1 SIL 2 Certificates ...........................................................3

1.1 XNX Gas Detector Transmitter .............................3

2 Overview .........................................................................4

3 Safety Parameters .........................................................5

3.1 Interval of Proof Testing .......................................5

4 Fault Diagnostic Time Interval ......................................6

5 Proof Test .......................................................................6

5.1 Purpose of Proof Testing .....................................6

5.2 Expected Outcome of Proof Testing ...................6

5.3 Tolerance of Output Current Levels ....................6

6 Proof Testing Procedure ...............................................7

6.1 Checking................................................................7

6.1.1 Force mA Output ...............................................7

6.1.2 Zero Gas mA Output ..........................................7

6.1.3 Calibration Gas mA Output ..............................7

6.2 Adjusting ...............................................................7

6.2.1 Calibrate 4.0 mA and 20.0 mA ..........................7

6.2.2 Zero Gas Calibration and Span Calibration ....8

6.2.2.1 Zero Gas Calibration ...................................8

6.2.2.2 Span Calibration .........................................9

6.3 Verifying mA Settings .........................................10

6.4 Testing .................................................................11

6.4.1 Fault and Alarm State ......................................11

6.4.2 Gas Verification ................................................12

XNX Universal Transmitter

SIL 2 Certiﬁcates 3XNX Gas Detector Transmitter

1 SIL 2 Certiﬁcates

1.1 XNX Gas Detector Transmitter

XNX Universal Transmitter

Overview 4XNX Gas Detector Transmitter

2 Overview

IEC 61508 is a generic functional safety standard. Functional safety

is deﬁned in this standard as “part of the overall safety relating to the

Equipment Under Control (EUC) and the EUC control system which

depends on the correct functioning of the E/E/PES1 safety related

systems, other technology safety-related systems, and external risk

reduction facilities.”

A system is considered to be functionally safe if the random and

systematic faults do not kill or injure humans, pollute the environment,

and do not result in the loss of equipment or production.

A systematic fault is deﬁned as a failure with a deﬁnite cause. A random

fault can happen at any time and the cause is unclear. The terms fault

and failure can be used interchangeably.

A Safety Integrity Level-certiﬁed system can detect the majority of

safe and unsafe failures. XNX is SIL 2 capable per IEC 61508. XNX

is SIL 3 capable in a redundant system per IEC 61508. Table 1 and

Table 2 below outline a system’s safety integrity level in relation to its

average probability of failure to perform its design function on demand

and probability of dangerous failure per hour.

Table 1. Average Probability of Failure to Perform Its Design Function on Demand (Low Demand

System)

Safety Integrity

Level

Low demand mode of operation (Average probability of

failure to perform its design function on demand (PFD))

4≥ 10-5 to < 10-4

3≥ 10-4 to < 10-3

2≥ 10-3 to < 10-2

1≥ 10-2 to < 10-1

1 Electrical/electronic/programmable electronic systems

Table 2. Probability of a Dangerous Failure Per Hour (High Demand System)

Safety Integrity

Level

High demand or continuous mode of operation

(Probability of a dangerous failure per hour (PFH))

4≥ 10-9 to < 10-8

3≥ 10-8 to < 10-7

2≥ 10-7 to < 10-6

1≥ 10-6 to < 10-5

NOTE:

The XNX system is Type B. A Type B system uses controllers

or programmable logic per IEC 61508.

The XNX product consists of a main board, a personality board, and

a sensor. The information presented in this manual is based on the

combination of the main board and personality board.

XNX

main

board

IR Personality

board

EC Personality

board

IR sensor

mV sensor

EC sensor

XNX Transmitter Sensor

Note: Only one personality board per XNX main board

mV Personality

board

This manual outlines the proof test procedure, a required operation to

maintain the XNX’s functional safety under low demand applications.

XNX Universal Transmitter

Safety Parameters 5Interval of Proof Testing

3 Safety Parameters

The safety parameters listed below are a combination of the main

board and personality board. These numbers were provided by TUV

in report 968/EL 665.00/09 (personality boards) and report 968/EZ

319.02/09 (main board).

For safety parameters of the individual sensors, refer to the XNX Safety

Parameters For Sensors White Paper.

Table 3. Safety Parameters of the XNX Transmitter (mV)

SFF PFDavg PFH

95% 4.8 x 10-4 1.12 x 10-7

Table 4. Safety Parameters of the XNX Transmitter (ECC)

SFF PFDavg PFH

97% 2.5 x 10-4 5.7 x 10-8

Table 5. Safety Parameters of the XNX Transmitter (IR)

SFF PFDavg PFH

97% 2.7 x 10-4 6.2 x 10-8

SFF: Safe Failure Fraction. A percentage of safe failures as compared

to all failures.

PFDavg

2: Average probability of failure to perform its design function

on demand.

PFH: Probability of a dangerous failure per hour.

2 PFDavg is a 1-year normalized value

3.1 Interval of Proof Testing

If the XNX is used in high demand systems, a proof test is not required.

If the XNX is used in low demand systems (deﬁned as 1 demand or

less per year) a proof test is required. Perform the proof test once a

year to comply with IEC 61508.

Section 6 Proof Testing Procedure outlines the actions that must be

completed for a proof test.

XNX Universal Transmitter

Fault Diagnostic Time Interval 6Purpose of Proof Testing

4 Fault Diagnostic Time Interval

XNX conducts approximately 30 diagnostics total on the main board

and personality board. These diagnostics occur at different time

intervals, with the longest interval at 24 hours. But when a fault is

detected, it is reported within 3 seconds. Refer to the XNX Technical

Manual for more information on diagnostics.

5 Proof Test

5.1 Purpose of Proof Testing

A proof test is a periodic test to detect failures in the system so that,

if necessary, the system can be restored to an “as new” condition or

as close as practical to this condition.

5.2 Expected Outcome of Proof Testing

The following features are checked and adjusted if required

• current output at different levels (4.0 mA and 20.0 mA)

• verifying zero gas and span gas calibration current output

• verifying current output of warnings and faults

• simulating warnings and faults

• validation of the current output of zero gas and/or span gas

calibration (required if the current output of zero gas and/or

span gas calibration had to be changed)

5.3 Tolerance of Output Current Levels

The tolerance for the output current levels is ± 0.1 mA.

Example: If the procedure requires the current output to be 4.0 mA,

the actual current reading at the controller end can range from 3.9 mA

to 4.1 mA.

XNX Universal Transmitter

Proof Testing Procedure 7Checking

6 Proof Testing Procedure

6.1 Checking

The purpose of checking is to ensure the mA output meets the

expected levels. If the current does not meet the expected levels, it

will have to be adjusted. If, after completing 6.1.1, 6.1.2, and 6.1.3, the

mA output does meet the expected levels, proceed to 6.3.

6.1.1 Force mA Output

1. Ensure the current can be measured at the controller end.

The current will be measured using the procedures outlined

in 6.1.1 to 6.1.3.

2. From the Main Menu, select the Test Menu ( ).

CAUTION

The mA output set in this menu will revert to the normal operating

values when exiting the Test Menu. For more information on setting

the mA output levels for normal operation, see mA Levels in the XNX

Technical Manual.

3. From the Test Menu, select Force mA Output ( ).

The New mA Output screen shows the existing mA output in

the left column. The user can adjust the output by changing

the value in the column on the right.

Figure 1. New mA Output Screen

4. Ensure the current at the controller end is 4.0 mA. If the current

is not 4.0 mA, refer to 6.2.1 to adjust the output.

5. Repeat steps #2-4 to check the output of 20.0 mA.

6.1.2 Zero Gas mA Output

The procedure for zero gas is not applicable to the ECC O2 sensor.

1. Apply zero gas to the sensor.

2. The current at the controller end should be 4.0 mA.

If the mA output is not at the expected level when applying

zero gas, perform a Zero Gas Calibration. Refer to 6.2.2 and

complete the procedure for a Zero Gas Calibration.

6.1.3 Calibration Gas mA Output

1. Apply calibration gas to the sensor.

2. The current measured at the controller end is related to the

percentage of gas applied.

Example: 100% of full gas concentration is equivalent to

20.0 mA. If 75% of the full scale gas concentration is applied,

the mA output should be 16.0 mA.

If the mA output is not at the expected level when applying

calibration gas, refer to 6.2.2 and perform a Zero Gas Calibration

and a Span Gas Calibration.

6.2 Adjusting

Perform the following procedures if 4.0 mA and 20.0 mA were not

measured at the controller end. If the correct currents were measured,

proceed to 6.3.

The current must be measured at the controller end in 6.2.1 and 6.2.2.

6.2.1 Calibrate 4.0 mA and 20.0 mA

1. From the Main Menu, select the Test Menu ( ).

2. Then select Force mA output ( ).

3. Adjust the current output in the column on the right until the

current at the controller end is 4.0 mA.

XNX Universal Transmitter

Proof Testing Procedure 8Adjusting

Figure 2. Adjusting Current

4. Once the new value is entered, use the switches to move

to the ‘3’ and select ✓ to set the mA output.

If the 20.0 mA output was not equal to 20.0 mA, complete steps #3-4.

6.2.2 Zero Gas Calibration and Span Calibration

The following section outlines the steps for calibrating the attached

XNX sensors. For calibration information for speciﬁc sensors, refer to

the XNX Technical Manual.

1. If using a compressed gas cylinder, push the calibration gas

ﬂow housing onto the bottom of the sensor and apply the gas.

2. Access the Calibration Menu.

Figure 3. Gas Calibration Menu

NOTE:

The Gas Calibration Menu is for both Zero Gas and Span Gas

Calibration.

6.2.2.1 Zero Gas Calibration

Sensor Reading

at Current Settings

Figure 4. Zero Gas Calibration Screen

As the sensor detects the zero gas and the concentration

increases, the values displayed will reflect the changing

concentration. When the concentration values are stable select

✓ to allow the XNX to calculate the zero adjustment. Selecting

✖ will return to the Gas Calibration Menu.

Figure 5. Zero Gas Calibration in Progress

3. If the Zero Gas Calibration is successful, the Zero Passed

screen displays.

Figure 6. Zero Gas Calibration Passed

XNX Universal Transmitter

Proof Testing Procedure 9Adjusting

6.2.2.2 Span Calibration

NOTE:

If a Span Calibration is not required, select ✖ to skip the Span

Calibration and return to the Calibration Menu.

1. When the Zero Gas Calibration is complete, the Span

Concentration screen appears. The gas concentration for the

Span Gas Calibration can be changed.

If the Span Calibration is skipped, the Gas Calibration screen

displays.

Figure 7. Span Gas Concentration Screen

2. Enter the concentration of the span gas by selecting ✓ to

choose the ﬁrst digit and use the switches to increment or

decrement the values. Use ✓ to accept the new value and move

to the next digit. Continue until all digits have been selected.

Sensor Reading

at Current Settings

Calibration Gas

Concentration

Figure 8. Span Calibration Screen

3. Apply the span gas. As the sensor detects the gas and the

concentration increases, the values displayed will reﬂect the

changing concentration. When the concentration values are

stable select ✓ to perform the span. The Span Calibration

process also determines whether the sensor is within the

proper range to accurately detect the target gas.

Selecting ✖ will cancel the span calibration and return to the

Gas Calibration Menu.

4. When the sensor has completed the calibration and the span

algorithms have determined that it is within range, the Span

Passed screen will appear.

Figure 9. Span Passed Screen

XNX Universal Transmitter

Proof Testing Procedure 10 Verifying mA Settings

If the calibration is not successful, the Span Failed screen will display.

Selecting ✓ will return to the Span Concentration screen to begin

the span calibration again. Selecting ✖ will exit Span Calibration and

return to the Gas Calibration Menu.

Arrow indicates

gas values too low

Selecting ‘✔’ returns to

the Span Concentration

screen

Figure 10. Span Calibration Failed

Once the Zero Gas and Span Gas calibrations are completed

successfully, the user will be prompted to

• exit with inhibit off,

• exit with inhibit on, or

• not exit.

Figure 11. Exiting Zero Gas and Span Gas calibrations

WARNING

While XNX is in Inhibit Mode, alarms are silenced. This will prevent

an actual gas event from being reported. Inhibit Mode must be reset

after testing or maintenance activities.

6.3 Verifying mA Settings

The mA levels output for inhibiting alarms during maintenance/testing,

warnings triggered by the XNX, overrange conditions, Beam Blocked

and Low Signal for the Searchpoint Optima Plus and Searchline Excel

gas detectors must be veriﬁed.

1. From the Main Menu, select the Conﬁgure Menu ( ). From

the Conﬁgure Menu, select mA Levels.

Figure 12. mA Levels Menu

2. Use the switches to move to the mA output to be changed

and use ✓ to select it.

✓

Figure 13. Set mA Levels for Warning

3. Refer to Table 6 for the mA levels. If the values do not match

the values in the table, proceed to step #4 to adjust the values.

NOTE

If the values for the faults and warnings have been changed

from the default settings since installation, ensure the current

output matches those changed values.

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