RKI Instruments 61-1000RK-05 Manual de usuario

www.rkiinstruments.com

61-1000RK-05

Combustible Gas Detector

Operator’s Manual

Part Number: 71-0087RK

Revision A

Released: 12/14/05

61-1000RK-05 Combustible Gas Detector• 2

Product Warranty

RKI Instruments, Inc., warranties gas alarm equipment sold by us to be free from defects

in materials, workmanship, and performance for a period of one year from date of

shipment from RKI Instruments, Inc. Any parts found defective within that period will be

repaired or replaced, at our option, free of charge. This warranty does not apply to those

items which by their nature are subject to deterioration or consumption in normal service,

and which must be cleaned, repaired, or replaced on a routine basis. Examples of such

items are:

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or

repair procedures not in accordance with the operator’s manual. This warranty indicates

the full extent of our liability, and we are not responsible for removal or replacement costs,

local repair costs, transportation costs, or contingent expenses incurred without our prior

approval.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER

WARRANTIES AND REPRESENTATIONS, EXPRESSED OR IMPLIED,

AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF

RKI INSTRUMENTS, INC., INCLUDING BUT NOT LIMITED TO, THE

WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS,

INC., BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL

LOSS OR DAMAGE OF ANY KIND CONNECTED WITH THE USE OF

ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR

OPERATE PROPERLY.

This warranty covers instruments and parts sold to users by authorized distributors,

dealers, and representatives as appointed by RKI Instruments, Inc.

We do not assume indemniﬁcation for any accident or damage caused by the operation of

this gas monitor, and our warranty is limited to the replacement of parts or our complete

goods.

a) Absorbent cartridges d) Batteries

b) Pump diaphragms and valves e) Filter elements

c) Fuses

61-1000RK-05 Combustible Gas Detector• 3

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Speciﬁcations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Combustible Gas Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Mounting the Combustible Gas Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Wiring the Combustible Gas Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Startup

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Replacing the Combustible Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Assembling the Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

61-1000RK-05 Combustible Gas Detector• 4

Overview

This manual describes the 61-1000RK-05 combustible gas detector (internal ampliﬁer

type). This manual also describes how to install, start up, maintain, and calibrate the

detector when it is used with a gas monitoring controller. A parts list at the end of this

manual lists replacement parts and accessories for the combustible gas detector.

Speciﬁcations

WARNING: Do not use this product in a manner not speciﬁed in this instruction

manual.

Table 1 lists speciﬁcations for the combustible gas detector.

NOTE: The following symbol on the detector label is a caution to the user to refer to this

documentation for installation and operation instructions:

Table 1: 61-1000RK-05 Speciﬁcations

Target Gas Combustible gas (Methane Calibration Standard)

Area Classiﬁcation Explosionproof for Class I, Groups B, C, and D

Sampling Method Diffusion

Detection Range 0 to 100% LEL

Response Time 90% in 45 seconds

61-1000RK-05 Combustible Gas Detector• 5

Description

This section describes the components of the combustible gas detector. The detector

includes the sensing elements, ﬂame arrestor, ﬂame arrestor guard, detector housing, and

detector leads.

Sensing elements

Two sensing elements are protected within the detector assembly. Through a series of

thermal and electronic reactions, these elements produce an electrical output that is

proportional to the detection range of the detector.

Flame arrestor

The porous ﬂame arrestor allows the target gas to diffuse into the detector assembly and

contact the sensing elements. The ﬂame arrestor also contains sparks within the detector.

Flame arrestor guard

The ﬂame arrestor guard is permanently bonded to the detector housing and protects the

ﬂame arrestor from impact damage.

Detector housing

The sensing elements and ﬂame arrestor are installed within the detector housing.

Mounting threads (1/2 in. NPT) at the top of the detector allow you to mount the

combustible gas detector into the bottom conduit hub of the junction box. A rainshield

screws onto the bottom of the detector. The rainshield helps protect the detector from

debris in the monitoring environment.

Detector leads

Four color-coded leads extend from the top of the detector. The leads allow you to connect

the combustible gas detector to the ampliﬁer.

Junction Box

The junction box allows you to install the detector at a mounting site that is remote from a

controller, and it protects the detector wiring connections. Two conduit hubs allow you to

mount the detector to the junction box and connect the wiring from the detector to a

controller. Three spacers installed on the back of the junction box control the distance of

the junction box from a mounting surface and insure that there is enough room to install a

calibration cup on the detector during calibration.

The bottom conduit hub includes a 3/4 in. x 1/2 in. reducer that allows you to screw the

detector into the hub. The terminal block within the junction box facilitates the wiring

process. Acover on the front of the junction box allows access to the interior of the

junction box.

61-1000RK-05 Combustible Gas Detector• 6

Installation

This section describes procedures to mount the combustible gas detector in the

monitoring environment and wire the detector to a controller.

Mounting the Combustible Gas Detector

1. Select a mounting site that is representative of the monitoring environment. Consider

the following when you select the mounting site.

•Select a site where the detector is not likely to be bumped or disturbed. Make sure

there is sufﬁcient room to perform start-up, maintenance, and calibration

procedures.

• Select a site where the target gas is likely to be found ﬁrst. For lighter gases,

mount the detector near the ceiling; for heavier gases, mount the detector near the

ﬂoor.

Figure 1: Mounting the Combustible Gas Detector

2. At the mounting site you select, hang or mount the junction box with the detector

facing down (see Figure 1).

61-1000RK-05 Combustible Gas Detector• 7

Wiring the Combustible Gas Detector to a Controller

WARNING: Always verify that the power to the controller is off before you make

wiring connections.

1. Turn off the controller.

2. Turn off or unplug incoming power at the power source end.

3. Remove the cover from the junction box. If the detector is already installed in the

junction box, go to step 6.

4. Guide the detector leads through the bottom conduit hub of the junction box, then

screw the mounting threads of the detector into the conduit hub.

5. Connect the detector leads to the terminal block in the junction box.

6. Guide a four-conductor, shielded cable or four wires in conduit through the top

conduit hub of the junction box.

WARNING: To maintain the explosion proof classiﬁcation of the LEL detector/junction

box combination, a conduit seal must be used at the junction box conduit

hub used for wiring to the controller.

7. Connect the wires to the terminals opposite the detector leads.

CAUTION:

Leave the shield drain wire insulated and disconnected at the detector. You will

connect the opposite end of the cable’s drain wire at the controller.

8. Secure the junction box cover to the junction box.

9. Route the cable or wires in conduit leading from the detector through one of the

conduit hubs at the controller.

CAUTION:

Do not route power and detector wiring through the same conduit hub. The power

cable may disrupt the transmission of the detector signal to the controller.

61-1000RK-05 Combustible Gas Detector• 8

Figure 2: Wiring the Combustible Gas Detector to a Controller

Combustibles

Detector

DetectorWires

Controller LEL

Detector

Terminals

Green

Red

Green

Red

Terminal Strip

Black

White

Black

J-box

61-1000RK-05 Combustible Gas Detector• 9

Start Up

This section describes procedures to start up the combustible gas detector and place the

detector into normal operation.

Introducing Incoming Power

1. Complete the installation procedures described earlier in this manual.

2. Verify that the power wiring to the controller is correct and secure. Refer to the

controller instruction manual.

3. Turn on or plug in the incoming power at the power source end, then turn on the

controller.

4. Verify that the controller is on and operating properly. Refer to the controller

instruction manual.

CAUTION:

Allow the detector to warm up for 5 minutes before you continue with the next

section, “Setting the Zero Reading.”

Setting the Zero Reading

CAUTION:

If you suspect the presence of combustible gas in the monitoring environment, use

the zero air calibration cylinder to introduce “fresh air” to the detector and verify an

accurate zero reading.

1. Verify that the detector is in a fresh air environment (environment known to be free of

combustible gas).

2. Verify a reading of 0% LEL at the controller.

If the display reading is 0% LEL, start up is complete. The combustible detector is in

normal operation. If the display reading is not 0% LEL, continue with step 3.

3. Perform a zeroing operation at the controller. See the controller instruction manual for

directions.

61-1000RK-05 Combustible Gas Detector• 10

Maintenance

This section describes maintenance procedures. It includes preventive maintenance,

troubleshooting, and component replacement procedures.

Preventive Maintenance

This section describes a preventive maintenance schedule to ensure the optimum

performance of the combustible gas detector. It includes daily, monthly, and quarterly

procedures.

Daily

Verify a display reading of 0% LEL at the controller. Investigate signiﬁcant changes in the

reading.

Monthly

This procedure describes a test to verify that the combustible gas detector responds

properly to the target gas.

WARNING: The controller is not an active gas monitoring device during the response

test procedure.

NOTE:

Performing a response test on the combustible detector may cause alarms. Be

sure to put the controller into its calibration program or disable external alarms

before performing this test

1. Place the controller into its calibration program or disable external alarms.

2. Verify that the controller display reading is 0% LEL.

If the controller reading is not 0% LEL, set the zero reading then continue this

procedure. See the controller instruction manual for directions to set the zero reading.

3. Screw the calibration cup over the bottom of the detector.

4. Use the sample tubing to connect the regulator to the calibration cup.

5. Screw the regulator into the calibration cylinder. The sample will begin to ﬂow.

6. When the reading at the controller stabilizes, verify that the reading is within ± 10% of

the gas concentration.

NOTE:

If the readings are not within ± 10% of the gas concentration, calibrate the

detector as described in the Calibration section of this manual.

7. Unscrew the regulator from the calibration cylinder, then disassemble the calibration

kit as described in the calibration section of this manual.

8. When the display reading falls below the alarm setpoints, return the controller to

normal operation.

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