RKI Instruments 61-1006RK User manual

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61-1006RK/61-0192RK
Combustible Gas Detector
Operator’s Manual
Part Number: 71-0228RK
Revision: P1
Released: 9/26/11

61-1006RK/61-0192RK Combustible Gas Detector
WARNING
Read and understand this instruction manual before operating
detector. Improper use of the detector could result in bodily harm
or death.
Periodic calibration and maintenance of the detector is essential
for proper operation and correct readings. Please calibrate and
maintain this detector regularly! Frequency of calibration
depends upon the type of use you have and the sensor types.
Typical calibration frequencies for most applications are between
6 and 12 months, but can be required more often or less often
based on your usage.

61-1006RK/61-0192RK Combustible Gas Detector
Product Warranty
RKI Instruments, Inc. warrants 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

61-1006RK/61-0192RK Combustible Gas Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IR LEL Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting the Combustible Gas Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiring the Combustible Gas Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacing the IR LEL Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

61-1006RK/61-0192RK Combustible Gas Detector • 1
Overview
This manual describes the 61-1006RK combustible gas detector. This manual also
describes how to install, start up, maintain, and calibrate the detector when 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.
The 61-1006RK combustible gas detector includes a junction box. This manual may also be
used for the 61-0192RK combustible gas detector which does not include a junction box
and is normally mounted in one of a controller’s conduit hubs. If you are using a
61-0192RK combustible gas detector, disregard all references to the junction box and
junction box terminal block.
Specifications
Table 1 lists specifications for the combustible gas detector.
WARNING: When using the 61-1006RK/61-0192RK, you must follow the instructions
and warnings in this manual to assure proper and safe operation of the
61-1006RK/61-0192RK and to minimize the risk of personal injury. Be sure
to maintain and periodically calibrate the 61-1006RK/61-0192RK as
described in this manual.
Table 1: 61-1006RK Specifications
Target/Calibration Gas With Junction Box
61-1006RK-CH4: Methane
Without Junction Box
61-0192RK-CH4: Methane
Area Classification Explosionproof for Class I, Groups B, C, and D
Sampling Method Diffusion
Detection Range 0 to 100% volume
Response Time 90% in 45 seconds
Accuracy ± 5% of reading or ± 2% of full scale (whichever is greater)

2 • 61-1006RK/61-0192RK Combustible Gas Detector
Description
The 61-1006RK combustible gas detector is calibrated to methane. The detector is an
infrared type of detector which has some advantages over a catalytic type of combustible
detector. The infrared detector will generally have a longer service life than a catalytic
detector, it will require calibration less often, and it can detect combustible gas even if
there is no oxygen in the sample which allows detection of combustible gas in an inert
atmosphere.
This section describes the components of the 61-1006RK. They include the infrared LEL
detector and the junction box.
Infrared LEL Detector
The infrared LEL detector is made up of a miniature infrared combustible gas LEL
detector housed and encapsulated in a pipe nipple. The pipe nipple has 3/4 inch NPT
threads on each end and a 1-1/4 inch hex that allows removal or installation of the
detector with a wrench. A porous flame arrestor coated with a hydrophobic film that
repels liquids is on one end of the detector and allows sample gas to enter the detector.
Four color coded leads, red, white, green, and black, extend from the other end of the
detector. The leads allow you to connect the detector to the terminal block in the junction
box.
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 3/4” NPT conduit hubs
allow you to mount the detector to the junction box and connect the wiring from the
detector to a controller. The terminal block within the junction box facilitates the wiring to
the detector. A cover on the front of the junction box allows access to the interior of the
junction box. Three spacers installed on the back of the junction box control the distance of
the junction box from a mounting surface and ensure that there is enough room to install a
calibration cup on the detector during calibration.

61-1006RK/61-0192RK Combustible Gas Detector • 3
Installation
This section describes procedures to mount the combustible gas detector in the
monitoring environment and wire it 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).
2.70 .38
Rubber
Spacers
3X
J-Box
.75
3/4 NPT
Female
3.65
CH4 IR Detector
7.10 max

4 • 61-1006RK/61-0192RK Combustible Gas Detector
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 power to the controller.
3. If the detector is mounted remotely from a controller using the junction box, proceed
to step 4.
If the detector is mounted directly to a controller, it is normally factory wired. Confirm
that the detector’s wires are connected to the appropriate controller detector terminals
and skip to “Start Up” on page 6. See Figure 2, the controller operator’s manual, and
the controller’s detector head specification sheet for the 61-0192RK-CH4 detector for
the wiring connections.
4. Remove the cover from the junction box.
5. Guide a four-conductor, shielded cable or four wires in conduit through the unused
conduit hub of the junction box. Use appropriate conduit fittings and construction
technique for the environmental rating and hazardous location classification of the
junction box. The junction box is rated NEMA 4X and classified explosion proof for
Class I, Groups B, C, and D.
6. Connect the detector leads to the terminal block in the junction box.
CAUTION: Leave the shield drain wire insulated and disconnected at the 61-1006RK. You will
connect the opposite end of the cable’s drain wire at the controller.
7. Secure the junction box cover to the junction box.
8. Route the cable or wires in conduit leading from the detector through one of the
conduit hubs at the controller housing. Use appropriate conduit fittings and
construction technique for the environmental rating of the controller. RKI controllers
are typically rated NEMA 4X.
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.
9. Connect the wires to the applicable controller terminal strip. See the controller
operator’s manual and the controller’s detector head specification sheet for the
61-1006RK-CH4 detector.
10. If using shielded cable, connect the cable’s drain wire to an available chassis ground at
the controller. RKI controllers typically have a ground stud that is a convenient
grounding location.

61-1006RK/61-0192RK Combustible Gas Detector • 5
Figure 2: Wiring the Combustible Gas Detector to a Controller
Controller Housing
Controller LEL
Detector
Terminals
Red
White
Green
Black
Cable Shield
White
Green
Black
CH4 IR Detector
Red

6 • 61-1006RK/61-0192RK Combustible Gas Detector
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 operator’s manual.
3. Turn on or plug in power to the controller, then turn on the controller.
4. Verify that the controller is on and operating properly. Refer to the controller
operator’s 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
WARNING: Do not remove the junction box cover while the circuits are energized
unless the area is determined to be non-hazardous. Keep the junction box
cover tightly closed during operation.
CAUTION: If you suspect the presence of combustible gas in the monitoring environment, use a
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 and toxic gases and of normal oxygen content, 20.9%).
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 operator’s manual for
directions.