Safety Manual

XNXTM Universal Transmitter

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

1 SIL 2 Certificates
1.1 XNX Gas Detector Transmitter

SIL 2 Certificates

XNX Gas Detector Transmitter

XNX Universal Transmitter

2 Overview

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

Safety Integrity
Level
4
3
2
1

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.

High demand or continuous mode of operation

(Probability of a dangerous failure per hour (PFH))
10-9 to < 10-8
10-8 to < 10-7
10-7 to < 10-6
10-6 to < 10-5

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.

NOTE:

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.

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.

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

or programmable logic per IEC 61508.

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

safe and unsafe failures. XNX is SIL 2 capable per IEC61508. XNX
is SIL 3 capable in a redundant system per IEC 61508. Table 1 and
Table 2 below outline a systems 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.

XNX Transmitter

XNX
main
board

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))

10 to < 10

3
2
1

10-4 to < 10-3

10-3 to < 10-2
10-2 to < 10-1

-5

Sensor

IR Personality
board

IR sensor

mV Personality
board

mV sensor

EC Personality
board

EC sensor

Note: Only one personality board per XNX main board

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

maintain the XNXs functional safety under low demand applications.

-4

1 Electrical/electronic/programmable electronic systems

Overview

XNX Gas Detector Transmitter

XNX Universal Transmitter

3 Safety Parameters

3.1 Interval of Proof Testing

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 report968/EZ
319.02/09 (main board).

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.

For safety parameters of the individual sensors, refer to the XNX Safety
Parameters For Sensors White Paper.

Section 6 Proof Testing Procedure outlines the actions that must be

completed for a proof test.

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

SFF

PFDavg

PFH

95%

4.8 x 10

1.12 x 10-7

-4

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.
PFDavg2: 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

Safety Parameters

Interval of Proof Testing

XNX Universal Transmitter

4 Fault Diagnostic Time Interval

5 Proof Test

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.

5.1 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 3.9mA
to 4.1 mA.

Fault Diagnostic Time Interval

Purpose of Proof Testing

XNX Universal Transmitter

6 Proof Testing Procedure

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

6.1.2 Zero Gas mA Output

6.1 Checking

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

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.

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

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 ( ).

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
20.0mA. 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.

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.

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.

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.
Proof Testing Procedure

).

Checking

XNX Universal Transmitter

6.2.2.1 Zero Gas Calibration
Sensor Reading
at Current Settings
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.

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.

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 5. Zero Gas Calibration in Progress

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

screen displays.

Figure 3. Gas Calibration Menu

NOTE:

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

Proof Testing Procedure

Figure 6. Zero Gas Calibration Passed

Adjusting

XNX Universal Transmitter

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.

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.

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 9. Span Passed Screen

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.
Calibration Gas
Concentration

Sensor Reading
at Current Settings

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.
Proof Testing Procedure

Adjusting

XNX Universal Transmitter

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

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 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 12. mA Levels Menu

2. Use the
and use

switches to move to the mA output to be changed

to select it.

Figure 13. Set mA Levels for Warning

Figure 11. Exiting Zero Gas and Span Gas calibrations

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.

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.

Proof Testing Procedure

10

Verifying mA Settings

XNX Universal Transmitter

6.4 Testing

Table 6. Set mA Levels

Signal*
I
W
O
B**
L**

Inhibit
Warning
Overrange
Beam Blocked
Low Signal

Default
2.0 mA
3.0 mA
21.0 mA
1.0 mA
1.0 mA

Output (mA)
Min
1.0
1.0
20
1.0
1.0

6.4.1 Fault and Alarm State

Max
3.5
3.5
22
4.0
4.0

The mA output of the faults and alarm states should be simulated and
the current output at the controller end should be within tolerance.
Refer to Table 6 for the current values for the fault and alarm states.
1. From the Test Menu, select Alarm/Fault Simulation.

*Faults are set to 1 mA and are not user-selectable

**Beam blocked and Low Signal apply only to Excel sensors.

4. Using the
switches, increment or decrement the value
until the desired value appears. Then use to confirm the
value and move to the next setting. Repeat for each setting
that must be changed.
The available output range for Inhibit, Warning, Beam Blocked and
Low Signal is from 1.0 to 4.0 mA and for an overrange condition, the
range is 20.0 to 22.0 mA. Refer to Section 5 Warnings/Faults in the
XNX Technical Manual for more information.

Figure 15. Alarm/Fault Simulation Screen

2. Figure 16 shows the menu choices simulating Alarm 1, Alarm 2,

Warning, or a Fault. Selecting the return arrow icon will display
the Alarms/Fault Reset Menu.

5. Once all changes have been made, use the

switches
to move to the 3 and use on the front panel to save the
settings.

Figure 16. Alarm/Fault Simulation Menu

3. Selecting an alarm level to simulate will activate a confirmation

screen.

Figure 14. mA Settings Saved

NOTE:

Figure 17. Confirmation

Selecting will simulate the selected alarm. If the

selected, the simulation is aborted.

If 3 is not selected, none of the changes will be saved.

Proof Testing Procedure

11

is

Testing

XNX Universal Transmitter

4. To simulate a Warning or Fault from the XNX, select the
appropriate icon from the menu.

As in an alarm simulation, a confirmation screen will appear.

Figure 21. Alarm/Fault Reset Screen

Figure 18. Warning and Fault Simulation Screens

5. As in an alarm simulation, a confirmation screen will appear.

Selecting will simulate a warning or fault from the XNX. If
is selected, the simulation is aborted.

Selecting will reset all alarms, faults or warnings generated

by the simulation. If is selected, the simulation continues.

CAUTION
The alarms and faults generated by the simulation will not be
cleared from the XNX until alarms/faults are reset. Failure to reset
the alarms/faults upon exiting the simulation keeps the relays and
LEDs in alarm/fault mode.
6.4.2 Gas Verification

Figure 19. Fault Simulation Confirmation

6. Use Alarm/Fault Reset to reset alarms, faults or warnings

generated by the simulation.

To verify the mA output of Zero Gas and Calibration, refer to 6.1.2 and
6.1.3.
A different bottle of calibration gas and/or zero gas should be used
to verify the results.

Figure 20. Alarm/Fault Reset Screen

Proof Testing Procedure

12

Testing

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1998-0808 Release 2
February 2011
MAN0912_EMEAI
2011 Honeywell Analytics