MSA Ultima X Series User guide

Ultima®X Series

Gas Monitor

Safety Manual

SIL 2 Certified

The Ultima X Series Gas Monitor is qualified as an SIL

2 device under IEC 61508 and must be installed, used,

and maintained in accordance with this manual if

compliance with this IEC functional safety standard

is desired. Failure to do so can result in a reduced

safety level.

In the U.S., to contact your nearest stocking location, dial toll-free 1-800-MSA-INST

To contact MSA International, dial (724) 776-8626.

This manual is available on the internet at www.msasafety.com.

Inquiries can also be e-mailed to customer.service@msasafety.com.

Manufactured by

MSA NORTH AMERICA

1000 Cranberry Woods Drive, Cranberry Township, PA 16066

(L)- Rev 1 Y-HLR 10100751

Table of Contents

Chapter 1,

Purpose and Scope . . . . . . . . . . . . . . . . . . . . . . .1-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Chapter 2,

Using the Ultima X Series Gas Monitors . . . . . .2-1

Safety Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Safety Integrity Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Safety Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Diagnostic Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Gas Detection Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Update Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Configuration and Calibration . . . . . . . . . . . . . . . . . . . . . .2-2

Proof Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Periodic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Periodic Sensor Replacement for Oxygen,

Toxic, and Catalytic Combustible sensors . . . . . . . . . . . .2-6

Cleaning Monitor Windows on the XIR Sensor . . . . . . . .2-6

Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Reliability Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Lifetime Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Environmental Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Application Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Required Output Load . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Required Compliance Voltage . . . . . . . . . . . . . . . . . . . . .2-9

Use of Wireless IR interface . . . . . . . . . . . . . . . . . . . . . . .2-9

Use of LCD Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Limitations Associated with Oxygen Monitoring . . . . . . . .2-9

Limitations Associated with Toxic Gas

and Combustible Gas Monitoring . . . . . . . . . . . . . . . . . .2-9

Chapter 3,

Terms and Definitions . . . . . . . . . . . . . . . . . . . . .3-1

List of Tables

Table 2-1. Proof Test for Ultima X Series Gas Detectors . . . .2-4

Table 2-2. Expected Alarm Relay States Gas Type . . . . . . . .2-5

1-1

Chapter 1,

Purpose and Scope

Purpose

In order to maintain the designed safety level (SIL 2) for installation and

operation of the MSA Ultima X Series Gas Monitors, this safety manual

provides the specific requirements of user responsibilities in the

following areas:

• proof testing

• transmitter repair and replacement

• reliability data

• product life

• environmental and application limits

• parameter settings.

Scope

This manual applies to the following analog output (4-20 mA) models:

• general-purpose Ultima XA monitor

• explosion-proof Ultima XE monitor

• explosion-proof Ultima XIR monitor.

Chapter 2,

Using the Ultima X Series Gas Monitors

Safety Function

The safety function of the Ultima X Gas Monitor is to:

• monitor gas concentration

• update outputs based on this monitoring.

• The outputs consist of:

• an analog output that reflects the gas concentration

• three alarm relay outputs

• one fault relay output.

• The analog output is a scaled 4-20 mA output value where:

• 4 mA represents 0% of range and

• 20 mA represents 100% of range.

• The alarm relay outputs allow for three independent,

configurable alarms which energize or de-energize

the coil when gas concentration exceeds the configurable

threshold values.

Safety Integrity Level

The Ultima X Gas Monitor is certified to meet the requirements of

Safety Integrity Level (SIL) 2 according to IEC 61508: 2010 for use in

low demand applications only.

• Oxygen, catalytic combustible and IR gases are SIL 2 w/ HFT = 0

(Hardware Fault Tolerance).

• Toxic gases are SIL 2 w/ HFT = 1 and SIL 1 w/ HFT = 0.

Safety Accuracy

The Ultima X Gas Monitor has a safety accuracy of 10%. This means

that internal component failures are listed in the device failure rate

if these failures cause an error of 10% or greater.

2-1

Diagnostic Response Time

The Ultima X Gas Monitor has a diagnostic response time of 24 hours.

This means that any detectable hardware failure is detected and

reported within 24 hours of fault occurrence. This time is equal to the

sum of the diagnostic test interval and the fault response time.

Gas Detection Times

The amount of time it takes to detect the presence of a gas varies

based on sensor type.

• Refer to this information in TABLE 3-1 of the Ultima X Series

Gas Monitor Instruction Manual (P/N 10036101).

Update Time

The state of the analog output and the relay outputs is updated every

second or sooner.

Setup

Installation

For installation, refer to instructions given in chapter 1 of the

Ultima X Series Gas Monitor Instruction Manual (P/N 10036101).

Configuration and Calibration

After installing the Ultima X Gas Monitor, a calibration must be done to

ensure proper operation. Perform the INITIAL Calibration procedure

given in chapter 2 of the Ultima X Series Gas Monitor Instruction

Manual (P/N 10036101).

No gas monitor configuration is required for the analog output.

However, configuration may be required to use the alarm outputs.

• Alarm relays are factory-enabled as non-latching, de-energized.

• Alarm relays activate when the monitor detects a gas concentration

level that exceeds setpoints.

• Factory configuration of alarms 1, 2, and 3 is generally

to set the alarms when 10%, 20%, and 30% of full scale reading

is exceeded, respectively.

2-2

NOTE: these settings are sensor-specific and may vary depending

on the sensor installed.

• The following sensor settings may be changed:

• setpoints

• direction of the alarm

• latching or nonlatching

• enabled or not enabled.

• If necessary, these items can be configured using the HART or

the Ultima X Controller. For details on how to make these

changes, refer to the Ultima/Ultima X Controller and Calibrator

manual (P/N 813379).

• When using HART, ensure safety function is not affected by

utilizing password protection or other security measures to

prevent unvalidated changes to instrument parameters.

• If alarm outputs will be used for safety-related functions, they

must be tested prior to system operation. Once alarm outputs

are configured, apply and remove gas to and from the system

to ensure that alarms:

• are set when the thresholds are exceeded

• latch if configured to do so, or clear if they are not.

Proof Testing

The recommended proof test for the Ultima X Gas Monitor is given in

TABLE 2-1. This is a periodic test recommended to help detect the

majority of any dangerous, undetected failures. The proof test coverage

for this test depends on sensor type. The details may be found in the

FMEDA report, which is available upon request.

Perform this test periodically at intervals known as the proof test

interval, which must be chosen to meet the probability of failure on

demand requirements for SIL 2.

2-3

Table 2-1. Proof Test for Ultima X Series Gas Detectors

TEST EXPECTED OUTCOME

Bypass the safety function or take None

appropriate action to avoid a false trip.

Note that calibration output signal must

be disabled so the analog output can

be measured during the test.

Perform a zero and span calibration as Analog output should read 4mA when zero

defined in the regular calibration section gas is connected. Analog output should be

of the Ultima X Series Gas Monitor scaled between 4 mA and 20 mA when span

instruction manual. While performing gas is applied. Exact analog output value

calibration, measure the analog output depends on span gas concentration. (e.g., if

when the device has zero gas or span span gas concentration is 50% LEL,

gas connected. If alarm relays are used, analog output should be 12 mA

check relay output

Reaction of external relays varies, based on

configuration. See TABLE 2-2 for detailed

relay reaction based on configuration. Any

activated relays should remain activated when

gas is removed if they are configured to latch;

otherwise,. relays deactivate when gas

is removed

If calibration is successful, the display shows

“END” after the zero and the span

calibration steps

If using alarm relays, and any alarm Relay should activate when span gas is

relay did not activate in the step 2 applied. When span gas is removed, alarm

because the alarm setpoint was higher should remain active if it is configured

than the span gas concentration, the to latch; otherwise, it should become inactive

relay should be activated in this test.

Change the setpoint for any such alarms

to a value just below the span gas

concentration. Now apply the span gas

as it was done during calibration

Remove the span gas When span gas is removed, the alarm should

remain active if it is configured to latch;

otherwise, it should become inactive

Change the setpoint back to the None

desired value

Remove the bypass or otherwise None

reverse the action taken in step 1

2-4

Table 2-2. Expected Alarm Relay States Gas Type

SETPOINT ALARM ALARM RELAY ALARM RELAY

SETTING STATE WITH STATE WITH

ZERO GAS SPAN GAS

APPLIED APPLIED

Lower than Above Set-point Not active Activated

span gas

concentration

Lower than Below Set-point Activated Not Active (NOTE:

span gas If alarm relays are

concentration configured as latching,

the alarm must

be cleared after the zero

gas is removed for this

state to be correct)

Higher than Above Set-point Not Active Not Active

span gas

concentration

Higher than Below Set-point Activated Activated

span gas

concentration

NOTE: Personnel performing the Ultima X proof test should be trained

in SIS operations, including bypass procedures, Ultima X

Monitor maintenance and company management of change

procedures.

Routine Maintenance

Besides proof testing, the following three maintenance procedures that

must be performed on the Ultima X gas monitors.

Periodic Calibration

To ensure accuracy and detect any sensor problems, calibrate the:

• XE and XA monitors a minimum of every three months

• XIR monitor according to the requirements as documented in the

Ultima X Series Gas Monitor instruction manual (P/N 10036101).

Calibrate monitors with catalytic combustible sensors when they have

been exposed to non-combustible chemicals known to reduce sensor

sensitivity (Silanes, Silicates, Silicones and Halides). Use the regular

calibration method given in the Ultima X Series Gas Monitor instruction

manual (P/N 10036101).

2-5

After calibration, read all messages on the LCD display and correct any

errors. Change the sensor immediately if the following messages occur:

• "SENSOR WARNING"

• "REPLACE SENSOR".

Refer to the "Limitations Associated with Toxic Gas and Combustible

Gas Monitoring" section later in this chapter.

Periodic Sensor Replacement for

Oxygen, Toxic, and Catalytic Combustible sensors

These sensors have a limited lifetime and must be replaced periodically

to ensure proper operation. Unless historical calibration records show

that sensors consistently last longer:

• replace oxygen and toxic sensors once per year

• replace catalytic combustible sensors every 18 months.

Due to environmental conditions, these sensors may require

replacement more or less frequently. If supported by calibration records:

• toxic sensors can be replaced as infrequently as every two years

• combustible sensors can be replaced as infrequently as every

three years.

• Do not exceed this replacement schedule.

Immediately replace sensors if the "SENSOR WARNING" or "REPLACE

SENSOR" messages occur after calibration.

Cleaning Monitor Windows on the XIR Sensor

NOTE: This does not apply to sensors other than the XIR sensor.

If the monitor windows on this sensor are dirty, the sensor may produce

erroneous readings. Whereas diagnostics detect this condition, the user

should also perform a periodic visual inspection of the windows. The

window is easily inspected after removing the environmental guard.

Frequency of required inspection is environmentally dependent.

In typical environments, windows never require cleaning due to the:

• environmental guard protection

• heating elements that prevent water condensation.

2-6

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