RKI Instruments 61-1020 User manual

RKI Instruments, Inc.
www.rkiinstruments.com
61-1020/61-0230
Molecular Property Spectrometer
Combustible Gas Detector
Operator’s Manual
Part Number: 71-0592
Revision: P2
Released: 10/14/22
TM

2• 61-1020/61-0230 Molecular Property Spectrometer 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. For most applications,
typical calibration frequencies are between 6 and 12 months but can
be more often or less often based on your usage.

61-1020/61-0230 Molecular Property Spectrometer Combustible Gas Detector • 3
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 two years 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:
• Absorbent cartridges
• Pump diaphragms and valves
•Fuses
•Batteries
• Filter elements
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 APARTICULAR PURPOSE. INNO
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.

4• 61-1020/61-0230 Molecular Property Spectrometer Combustible Gas Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MPS Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting the Combustible Gas Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring the Combustible Gas Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing the Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

61-1020/61-0230 Molecular Property Spectrometer Overview • 5
Overview
This manual describes the 61-1020 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 61-1020 combustible gas detector includes a junction box. This manual may also be used for
the 61-0230 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 61-0230 combustible gas
detector, disregard all references to the junction box and junction box terminal block.
Specifications
Table 1 specifies the detection range and accuracy for the 14 gases that the MPS sensor can
reliably detect at the same time.
Table 1: Detection Ranges and Accuracy
Target Gas Formula Detection Range Accuracy
(0 to 50% LEL)
Butane C4H10 0 - 100% LEL ± 5% LEL
Ethane C2H60 - 100% LEL ± 5% LEL
Hydrogen H20 - 100% LEL ± 5% LEL
Isobutane HC(CH3)30 - 100% LEL ± 5% LEL
Isobutylene C4H80 - 100% LEL ± 5% LEL
Isopropanol C3H8O 0 - 100% LEL ± 10% LEL
Methane CH40 - 100% LEL ± 3% LEL
Methyl Ethyl Ketone C4H8O 0 - 100% LEL ± 5% LEL
Octane C8H18 0 - 100% LEL ± 5% LEL
Pentane C5H12 0 - 100% LEL ± 5% LEL
Propane C3H80 - 100% LEL ± 6% LEL
Propylene C3H60 - 100% LEL ± 5% LEL
Toluene C7H80 - 100% LEL ± 12% LEL
Xylene C8H10 0 - 100% LEL ± 12% LEL
NOTE: The MPS sensor will respond to other combustible gases, but the accuracy has only
been determined for these 14 gases.

6• Applications 61-1020/61-0230 Molecular Property Spectrometer
WARNING: When using the 61-1020/61-0230, you must follow the instructions and warnings
in this manual to assure proper and safe operation of the 61-1020/61-0230 and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 61-1020/61-0230 as described in this manual.
Applications
The MPS combustible detector is most effective in the following applications:
• High concentrations of hydrogen sulfide (H2S) or silicones present where sensor
poisoning is a common problem
• High-humidity environments where catalytic or IR sensors may not hold up
• Environments more likely to have mixtures of hydrocarbons present
Table 2: Specifications
Target/Calibration Gas
With Junction Box
• 61-0230-CH4: Methane
• 61-0230-HC: General hydrocarbons (propane calibration standard)
Without Junction Box
• 61-1020-CH4: Methane
• 61-1020-HC: General hydrocarbons (propane calibration standard)
Area Classification Explosion-proof for Class I, Groups B, C, and D
Operating
Temperature Range
-20ºC to +50ºC (-4ºF to +122ºF)
Humidity Range 0 - 100% RH (non-condensing)
Pressure Range 80 to 120 kPa
Sampling Method Diffusion
Detection Range 0 to 100% LEL
Response Time 90% in 45 seconds
Dead Bands •Methane(CH
4): 3% LEL
• All other gases: 5% LEL

61-1020/61-0230 Molecular Property Spectrometer Description • 7
Description
The 61-1020 is a Molecular Property Spectrometer (MPSTM) type of detector which has some
advantages over a catalytic or IR type of combustible detector. The explosion-proof MPS detector
is immune to poisons, can be used in high humidity, can detect multiple gases simultaneously (see
Table 1), and does not require calibration as often as catalytic combustible sensors.
This section describes the components of the 61-1020: the MPS LEL detector and the junction
box.
Figure 1: Component Location
MPS Detector
The MPS LEL detector is made up of the MPS combustible gas LEL detector housed and
encapsulated in a pipe nipple. The pipe nipple has 3/4 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. Use the leads when connecting the detector to the terminal block in the
junction box.
Junction Box
The junction box allows installation of the detector at a mounting site that is remote from the
controller while protecting 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 insure that there is enough room to install a calibration cup on the detector during calibration.
J-Box
Green
Red
White
Rubber
Spacers,
3X
MPS LEL Detector
Black

8• Installation 61-1020/61-0230 Molecular Property Spectrometer
Installation
This section describes procedures to mount the combustible gas detector in the monitoring
environment and wire it to a controller.
If you purchased a 61-0230 detector that is factory installed and wired to a controller, detector
installation is not necessary, but the detector wiring can be confirmed as described in “Wiring the
Combustible Gas Detector to a Controller” on page 9.
Mounting the Combustible Gas Detector
1. Select a mounting site that is representative of the monitoring environment. Consider the
following when selecting 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 2: Mounting the Combustible Gas Detector
2. At the selected mounting site, hang or mount the junction box with the detector facing down
(see Figure 2).
2.70 .38
J-Box
3/4 NPT
Female
Rubber
Spacers,
3X
.75
3.65
MPS LEL Detector
7.10 MAX

61-1020/61-0230 Molecular Property Spectrometer Installation • 9
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 11. See Figure 3, the controller operator’s manual, and the
controller’s detector head specification sheet for the 61-0230 detector for the wiring
connections.
4. Remove the cover from the junction box.
WARNING: To maintain the explosion proof classification of the detector/junction box
combination, a conduit seal must be used within 18 inches of the junction box
conduit hub used for wiring to the controller. Adhere to your local electrical
code when installing the conduit seal.
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 wires to the terminal block in the junction box.
CAUTION: Leave the shield drain wire insulated and disconnected at the 61-1020.
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. Use appropriate conduit fittings and construction technique for the
environmental rating of the controller. RKI controllers are typically rated NEMA 4X, are not
explosion-proof, and must be installed in a non-hazardous location.
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 61-1020 detector.

10 • Installation 61-1020/61-0230 Molecular Property Spectrometer
Figure 3: Wiring the Combustible Gas Detector to a Controller
10. If using a 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.
Red
White
Green
Black
White
Green
Red
Detector Wires
Black
Terminal Strip
J-Box
Controller
LEL
Detector
Terminals
MPS LEL Detector
Cable Shield