RKI Instruments 61-1000RK-05 User manual

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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
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.

61-1000RK-05 Combustible Gas Detector• 11
Quarterly
Calibrate the detector as described in the Calibration section of this manual.
Troubleshooting
The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the combustible gas detector.
NOTE: This troubleshooting guide describes detector problems only. See the controller
operator’s manual for problems you may encounter with the controller.
Replacing the Combustible Detector
1. Turn off the controller.
2. Turn off power to the controller.
3. Remove the junction box cover.
4. Disconnect the detector leads from the terminal block inside the junction box. Note
the position of the color-coded leads as you remove them.
5. Unscrew the detector from the junction box.
6. Guide the detector leads of the replacement detector through the bottom conduit hub
of the junction box, then screw the mounting threads of the detector into the conduit
hub.
7. Connect the detector leads of the terminal block in the same position as the leads you
removed in step 4.
Table 2:Troubleshooting the Combustible Gas Detector
Condition Symptom(s) Probable Causes Recommended Action
Fail Condition • Controllerindicates a
fail condition. • The detector wiring is disconnected or
misconnected.
• The detector zero
signal is low enough to
cause a fail condition.
• The detector is
malfunctioning.
1. Verify that the detector wiring is
correct and secure.
2. Calibrate the detector.
3. If the fail condition continues, replace
the detector.
4. If the fail condition continues, contact
RKI for further instruction.
Slow or No
Response/
Difficult or
Unable to
Calibrate
• Detector responds
slowly or does not
respond to response
test.
• Unable to accurately
set the zero or
response reading
during calibration.
• Detector requires
frequent calibration.
Note: Under “normal”
circumstances, the
detector requires
calibration once every
three months.
Some applications may
require a more frequent
calibration schedule.
•Thecalibrationcylinder
is low, out-dated, or
defective.
• The detector is
malfunctioning.
1. Verify that the calibration cylinder
contains an adequate supply of a
fresh test sample.
2. If the calibration/response difficulties
continue, replace the detector.
3. If the calibration/response difficulties
continue, contact RKI for further
instruction.

61-1000RK-05 Combustible Gas Detector• 12
8. Turn on power to the controller.
9. Turn on the controller.
10. Secure the junction box cover to the junction box.
11. Calibrate the replacement detector as described in the Calibration section of this
manual.
Calibration
This section describes how to calibrate the combustible gas detector. It includes
procedures to assemble the calibration kit, set the zero reading, set the response reading
and return to normal operation.
WARNING: The controller is not an active gas monitoring device during the calibration
procedure.
Assembling the Calibration Kit
1. Screw the calibration cup onto the bottom of the detector.
2. Use the sample tubing to connect the regulator to the calibration cup.
NOTE : Do not screw the regulator into the calibration cylinder at this time.
3. Place the controller into its calibration program or disable external alarms.
NOTE: Calibrating the combustible detector may cause alarms. Be sure to put the
controller into its calibration program or disable external alarms before
continuing.
Setting the Zero Reading
CAUTION: If you suspect the monitoring environment is not free of combustible vapors, use the
calibration kit and a zero air calibration cylinder to introduce “fresh air” to the
detector and verify an accurate zero setting
1. Verify that the detector is in a fresh air environment.
2. Follow the directions in the controller’s instruction manual for setting the zero
reading.
Setting the Response Reading
1. Follow the directions in the controller’s instruction manual for setting the response
reading (span).
2. When the directions call for exposing the detector to gas, screw the regulator into the
cylinder and allow the gas to flow to the detector until the reading at the controller
stabilizes, approximately 2 minutes, before continuing with the directions.
3. After setting the response reading, unscrew the regulator from the cylinder and
remove the calibration cup from the detector.

61-1000RK-05 Combustible Gas Detector• 13
NOTE: For convenience, leave the components of the calibration kit connected by the
sample tubing.
4. Allow about 15 seconds for the gas reading to decrease below the alarm points and
then return the controller to normal operation.
NOTE : If you do not allow the gas reading decrease below the alarm points, then
unwanted alarms may occur.
5. Verify that the controller display reading decreases and stabilizes at 0%LEL.
6. Store the components of the calibration kit in a safe and convenient place.
Parts List
Table 3 lists replacement parts and accessories for the 61-1000RK-05 combustible gas
detector.
Table 3: Parts List
Part Number Description
18-0400RK-01 Junction box with spacers
61-0140RK-05 Replacement combustible gas detector
71-0087RK 61-1000RK-05 Combustible Gas Detector Operator’s Manual (this docu-
ment)
81-0007RK-01 Calibration cylinder (50% LEL Hexane in air, 34 liter)
81-0012RK-01 Calibration cylinder (50% LEL Methane in air, 34 liter)
81-0076RK-01 Zero air calibration cylinder (34 liter)
81-1003RK Regulator, 0.5 liter/minute; continuous flow
(for 17 and 34 liter calibration cylinders)
81-1117RK Calibration cup