RKI Instruments 65-2405RK-04 User manual

65-2405RK-04
Combustible Gas Transmitter
Operator’s Manual
Part Number: 71-0280RK
Revision: P1
Released: 5/30/13
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65-2405RK-04 Combustible Gas Transmitter
WARNING
Read and understand this instruction manual before
operating transmitter. Improper use of the transmitter could
result in bodily harm or death.
Periodic calibration and maintenance of the transmitter is
essential for proper operation and correct readings. Please
calibrate and maintain this transmitter regularly! Frequency
of calibration depends upon the type of use you have and
the sensor types. Typical calibration frequencies for most
applications are between 3 and 6 months, but can be
required more often or less often based on your usage.
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65-2405RK-04 Combustible Gas Transmitter
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
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65-2405RK-04 Combustible Gas Transmitter
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Combustible Gas Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Calibration Cup/Splash Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Amplifier Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Detector Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting the Combustible Gas Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wiring the Detector to the Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring the Amplifier to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing Components of the Combustible Gas Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Determining Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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65-2405RK-04 Combustible Gas Transmitter • 1
Overview
This manual describes the 65-2405RK-04 combustible gas transmitter. This manual also
describes how to install, start up, configure, maintain, and calibrate the transmitter 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 transmitter.
Specifications
Table 1 lists specifications for the combustible gas transmitter.
WARNING: When using the 65-2405RK-04, you must follow the instructions and
warnings in this manual to assure proper and safe operation of the
65-2405RK-04 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 65-2405RK-04 as described in this
manual.
Table 1:Specifications
Description Specification
Target Gas Methane (CH4)
Area Classification Explosionproof for Class I, Groups B, C, and D
Sampling Method Diffusion
Signal Output 4 to 20 mA
Detection Range 0 to 100% LEL
Response Time 90% in 45 seconds
Operating Temperature -4°F to 122°F (-20°C to 50°C)
Accuracy ± 5% of reading or ± 2% of full scale (whichever is greater)
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2 • 65-2405RK-04 Combustible Gas Transmitter
Description
This section describes the components of the combustible gas transmitter. The transmitter
is a 4 - 20 mA type detector head. It consists of the combustible gas detector, calibration
cup/splash guard, amplifier, the amplifier junction box, and the detector junction box.
The two junction box configuration is intended for situations where the detector needs to
be installed at an inaccessible location. The detector junction box can be installed at the
inaccessible location and the amplifier junction box can be installed in a more readily
accessible area.
Figure 1: Combustible Gas Transmitter Component Location
Controller Terminal
Strip
Amplifier
LEL PWR/ SIG
G
S2 001
S
57-1053RK
BR W
Combustible Gas Detector
Amplifier J-Box
Detector J-Box
Terminal Strip
Jumper Pins,
Factory Use
Only
Factory Adjust
Pot
Factory Adjust Pot
Span Pot
Zero Pot
SPAN
ZERO
Sensor Current
m A
+ Test Point
- TestPoint
Detector Terminal
Strip
Calibration Cup/Splash Guard
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65-2405RK-04 Combustible Gas Transmitter • 3
Combustible Gas Detector
The combustible gas detector is a catalytic type detector that produces an electrical output
that corresponds to the detection range. It is packaged in a 1/2 inch NPT nipple with a
sintered metal flame arrestor on one end allowing ambient air to diffuse into the detector.
The flame arrestor also contains any sparks which may occur within the detector. The 1/2
inch NPT mounting threads at the top of the detector allow you to mount it into the
bottom conduit hub of the junction box. A rainshield screws onto the bottom of the
detector (flame arrestor end). The rainshield helps protect the detector from rain and
debris in the monitoring environment. Four color-coded leads extend from the top of the
detector. The leads allow you to connect the detector to the amplifier.
Calibration Cup/Splash Guard
A calibration cup/splash guard is installed on the rainshield of the combustible gas
detector. A fitting at the bottom of the calibration cup/splash guard allows a length of
tubing to be connected for calibration and routed to a more easily accessible location. The
calibration cup/splash guard also protects the detector.
Amplifier
The amplifier is located in the amplifier junction box. The amplifier converts the electrical
output from the detector to a 4 to 20 mA signal that corresponds to the detection range
and transmits the signal to a gas monitoring controller. A foam gasket that orients the
amplifier and keeps it from rotating is installed on the bottom of the amplifier. A label on
the amplifier indicates the detector drive current. This drive current is factory set and is
dictated by the combustible gas to which the detector is calibrated. Consult RKI
Instruments, Inc. if you plan to change the calibration gas for the transmitter, for example
from a methane calibration to a hexane calibration. The amplifier includes the detector
terminal strip, controller terminal strip, span pot, zero pot, and test points (see Figure 1).
Controller Terminal Strip
The controller terminal strip is a three position plug-in style terminal strip located near the
top of the amplifier. Use the controller terminal strip to wire the combustible gas
transmitter to a controller.
Detector Terminal Strip
The detector terminal strip is a four position plug-in style terminal strip located below the
controller terminal strip. Use the detector terminal strip to connect the combustible gas
detector to the amplifier.
NOTE: See “Wiring the Detector to the Amplifier” on page 6 for all wiring procedures
related to the transmitter.
Zero Pot
The zero pot is located in the upper left corner of the amplifier (see Figure 1). Use a small
flat blade screwdriver to turn the zero pot’s adjustment screw and adjust the amplifier’s
zero (fresh air) output during the start-up and calibration procedures. Turn the adjust-
ment screw clockwise to increase the zero output and counterclockwise to decrease the
zero output.
Span Pot
The span pot is located to the right of the zero pot (see Figure 1). Use a small flat blade
screwdriver to turn the span pot’s adjustment screw and adjust the amplifier’s gas
response output during the calibration procedure. Turn the adjustment screw clockwise to
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4 • 65-2405RK-04 Combustible Gas Transmitter
increase the gas response and counterclockwise to decrease the gas response.
CAUTION: The amplifier includes two additional potentiometers. They are factory-set. Do not
adjust them.
Test Points
The test points are on the left side of the amplifier (see Figure 1). The test points produce a
100 mV to 500 mV output that corresponds to the transmitter’s 4 to 20 mA output. Use the
test points and a voltmeter to measure the amplifier’s output during the start-up and
calibration procedures. The black test point in the lower left corner is the negative (-) test
point and the red test point below the zero pot is the positive (+) test point.
Amplifier Junction Box
The amplifier junction box protects the amplifier and wiring connections made to the
amplifier. Use the top 3/4’’ conduit hub to connect wiring from the amplifier to the
controller. Use the bottom 3/4” conduit hub to wire the remotely installed combustible
gas detector. Use the cover on the front of the junction box to access the interior of the
junction box. The amplifier is factory installed in the junction box. Three spacers installed
on the back of the junction box controls the distance of the junction box from a mounting
surface.
Detector Junction Box
The detector junction box is intended to be installed remotely from the amplifier junction
box. The combustible gas detector is factory installed in the bottom 3/4” conduit hub. A
terminal strip is provided for wiring connections and the detector is factory wired to one
side of this terminal strip. The other side of the terminal strip is for user-supplied wiring
to the detector terminal strip located in the amplifier junction box. This wiring should go
through the top 3/4” conduit hub. Three spacers installed on the back of the junction box
controls the distance of the junction box from a mounting surface.
Installation
This section describes procedures to mount the combustible gas transmitter in the
monitoring environment and wire the transmitter to a controller.
Mounting the Combustible Gas Transmitter
1. Select a mounting site that is representative of the monitoring environment. Consider
the following when you select the mounting site.
• For the amplifier junction box, select a site where the junction box is not likely to
be bumped or disturbed. Make sure there is sufficient room to perform start-up,
maintenance, and calibration procedures. The site should be easily accessible.
• For the detector junction box, 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.
• The junction boxes should be mounted no further than 200 feet from each other.
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65-2405RK-04 Combustible Gas Transmitter • 5
Figure 2: Mounting the Combustible Gas Transmitter
2. At the monitoring site you select, hang or mount the detector junction box with the
detector facing down (see Figure 2).
3. Install 3/16 inch I.D. flexible polyurethane tubing to the fitting at the bottom of the
calibration cup/splash guard and route it to an accessible area that is close to the
amplifier junction box. See the “Parts List” on page 19 for available tubing.
Rubber
Spacer,
3X
2.70 .38
J-Box
Combustible
Gas Detector
3.65
3/4 NPT
Female
Calibration
Cup/Splash
Guard
10.30 MAX
5.25
1.13
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6 • 65-2405RK-04 Combustible Gas Transmitter
Wiring the Detector to the Amplifier
WARNING: Always verify that the power to the controller is off before you make
wiring connections.
1. Confirm that no power is being applied to the amplifier. If the amplifier has already
been connected to a controller, turn off the controller and turn off or unplug power to
the controller.
2. Remove the detector junction box’s cover from the junction box.
3. Remove the amplifier junction box’s cover from the junction box.
4. Guide a four-conductor, shielded cable or four wires in conduit through the top
conduit hub of the detector junction box. To make wiring more convenient, use wire
colors that correspond to the detector wire colors: red, white, green, and black.
NOTE: Consult RKI Instruments, Inc. for cable lengths longer than 200 feet.
5. Connect the detector leads to the terminal block in the detector junction box.
6. Secure the detector junction box’s cover to the junction box.
7. Guide the other end of the four-conductor, shielded cable or four wires in conduit
through the bottom conduit hub of the amplifier junction box.
8. To gain access to a plug-in terminal strip for wiring, pull it out of its socket by
grasping the terminal strip and pulling. The detector strip is keyed so that the
controller and detector terminal strips cannot be reversed inadvertently.
9. Pull out the detector terminal strip and connect the four wires to the terminal strip as
follows (see Figure 3).
• Connect the wire corresponding to the detector’s red wire to the LEL “R”
terminal.
• Connect the wire corresponding to the detector’s white wire to the LEL “W”
terminal.
• Connect the wire corresponding to the detector’s green wire to the LEL “G”
terminal.
• Connect the wire corresponding to the detector’s black wire to the LEL “B”
terminal.
CAUTION: If shielded cable is used, leave the cable shield’s drain wire disconnected and
insulated at the detector junction box. You will connect the opposite end of the cable’s
drain wire to the amplifier junction box’s chassis (earth) ground.
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65-2405RK-04 Combustible Gas Transmitter • 7
Figure 3: Wiring the Detector to the Amplifier
10. Reinstall the detector terminal strip into its socket.
11. If shielded cable is used, connect the cable’s drain wire to an available chassis (earth)
ground at the amplifier junction box. The amplifier mounting screw is a convenient
grounding location. Install a lug on the shield drain wire or wrap the shield drain wire
around the mounting screw. Do not connect the shield drain wire at the detector
junction box.
GRB
PWR /SIG
WLEL S
Amplifier
Black
Green
White
Red
IR LELDetector
Cable
Shield
Detector
Terminal
Strip
Black
Green
White
Red
Amplifier
J-Box
Detector J-Box
Calibration Cup/Splash Guard
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8 • 65-2405RK-04 Combustible Gas Transmitter
Wiring the Amplifier to a Controller
1. Turn off the controller.
2. Turn off or unplug power to the controller.
3. Remove the amplifier junction box’s cover from the junction box.
4. Guide a three-conductor, shielded cable, or three wires in conduit through the top
conduit hub of the amplifier junction box.
5. Pull out the controller terminal strip, and connect the three wires to the terminal strip
as follows (see Figure 4).
• Connect the positive wire to the PWR/SIG “+” terminal.
• Connect the signal wire to the PWR/SIG “S” terminal.
• Connect the negative wire to the PWR/SIG “-” terminal.
CAUTION: If shielded cable is used, leave the cable shield’s drain wire disconnected and
insulated at the amplifier junction box. You will connect the opposite end of the
cable’s drain wire to the controller’s chassis (earth) ground.
6. Reinstall the controller terminal strip into its socket.
7. Secure the amplifier junction box’s cover to the junction box.
8. Route the cable or wires leading from the amplifier junction box through one of the
conduit hubs at the controller housing.
CAUTION: Do not route power and transmitter wiring through the same controller conduit hub.
The power cable may disrupt the transmission of the transmitter signal to the
controller.
9. Connect the wires to the applicable detector/transmitter terminal strip at the
controller as shown in Figure 4.
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65-2405RK-04 Combustible Gas Transmitter • 9
Figure 4: Wiring the Amplifier to a Controller
10. If shielded cable is used, connect the cable’s drain wire to an available chassis (earth)
ground at the controller. RKI controllers typically have a ground stud that can be used
to ground the cable’s drain wire.
Amplifier (Transmitter)
Cable Shield
- (DC Ground)
+ 24 VDC
4 - 20 mA In (S)
Controller or
Recording Device
Detector Wires
Green
White
Red
B
Amplifier
J-Box
R W G PWR /SIG
Black
LEL S
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10 • 65-2405RK-04 Combustible Gas Transmitter
Start Up This section describes procedures to start up the combustible gas transmitter and place the
transmitter 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 power to the controller.
4. Turn on the controller.
5. Verify that the controller is on and operating properly. Refer to the controller
operator’s manual.
NOTE: When first powered up, the transmitter will enter about a one minute period
when the 4-20 mA output is stabilizing and may be above the controller alarm
points or well below zero momentarily. RKI controllers have a one minute
warmup period when the controller does not display any gas reading or give any
alarm indication. The combustible gas transmitter’s 4-20 mA signal should be
stable by the time the controller’s warmup period is over.
CAUTION: Allow the detector to warm up for 5 minutes before you continue with the next
section, “Setting the Zero Signal”.
Setting the Zero Signal
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.
NOTE: If you can verify that the combustible gas transmitter is in a fresh air
environment, you do not need to apply zero air to the detector before adjusting
the zero reading.
The procedure below describes applying zero emission air, usually called zero air, using a
calibration kit that includes a calibration cup, calibration gas, sample tubing, and a fixed
flow regulator with an on/off knob. RKI Instruments, Inc. recommends using a 0.5 LPM
(liters per minute) fixed flow regulator.
1. Unscrew and remove the amplifier junction box’s cover from the junction box.
2. Set a voltmeter to measure in the millivolt (mV) range.
3. Plug the voltmeter leads into the test points on the amplifier. Plug the positive lead
into the red (+) test point; plug the negative lead into the black (-) test point.
4. Screw the regulator into the zero air calibration cylinder.
5. Use the flexible tubing coming from the calibration cup/splash guard to connect the
regulator to the calibration cup.
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65-2405RK-04 Combustible Gas Transmitter • 11
6. Turn the regulator’s on/off knob counterclockwise to open it. Gas will begin to flow.
7. Allow the gas to flow for the length of time determined in “Determining Response
Time” on page 16.
8. Verify a voltmeter reading of 100 mV (±2 mV).
9. If necessary, use a small flat-blade screwdriver to adjust the zero pot until the
voltmeter reading is 100 mV (±2 mV).
10. Turn the regulator’s on/off knob clockwise to close it.
11. Disconnect the calibration cup/splash guard’s flexible tubing from the regulator.
NOTE: Do not disconnect the flexible tubing from the calibration cup/splash guard.
12. Unscrew the regulator from the zero air calibration cylinder.
13. Store the components of the calibration kit in a safe and convenient place.
14. Remove the voltmeter leads from the test points.
15. Secure the junction box cover to the junction box.
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 transmitter. It includes daily, monthly, and quarterly
procedures.
Daily
Verify a display reading of 0 %LEL at the controller. Investigate significant changes in the
display reading.
Monthly
This procedure describes a test to verify that the combustible gas transmitter 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 gas transmitter may cause alarms.
Be sure to put the controller into its calibration mode or disable external alarms
before performing this test.
NOTE: The following procedure assumes the use of a calibration kit which includes a
calibration gas cylinder, a 0.5 LPM fixed flow regulator with an on/off knob, a
calibration cup for the detector, and a length of sample tubing.
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12 • 65-2405RK-04 Combustible Gas Transmitter
Preparing for the response test
1. Place the controller into its calibration mode or disable external alarms.
2. Verify that the controller display reading for the channel you are testing is 0 %LEL.
If the display reading is not 0 %LEL, set the zero reading of the transmitter as
described in “Start Up” on page 10, then continue this procedure.
3. Screw the regulator into the calibration cylinder.
4. Use the flexible tubing coming from the calibration cup/splash guard to connect the
regulator to the calibration cup.
5. Unscrew and remove the amplifier junction box’s cover from the junction box.
6. Set a voltmeter to measure in the millivolt (mV) range.
7. Plug the voltmeter leads into the test points on the amplifier. Plug the positive lead
into the red (+) test point; plug the negative lead into the black (-) test point.
8. Use the following formula to determine the correct test points output for the test
sample.
Output (mV) = (calibrating sample/fullscale) X 400 + 100
For example, with a test sample of 50 %LEL and a fullscale setting of 100 %LEL, the
correct output is 300 mV.
300 (mV) = (50/100) X 400 +100
Performing the response test
1. Turn the regulator’s on/off knob counterclockwise to open the regulator. Gas will
begin to flow.
2. Allow the gas to flow for the length of time determined in “Determining Response
Time” on page 16.
3. Verify that the reading is within ± 20% of the response reading you determined earlier.
NOTE: If the reading is not within ± 20% of the correct response reading, calibrate the
transmitter as described in “Calibration” on page 17 of this manual.
4. Turn the regulator’s on/off knob clockwise to close the regulator.
5. Unscrew the regulator from the calibration cylinder.
6. Disconnect the calibration cup/splash guard’s flexible tubing from the regulator.
NOTE: Do not disconnect the flexible tubing from the calibration cup/splash guard.
7. Remove the voltmeter leads from the amplifier test points.
8. Reinstall the amplifier junction box’s cover.
9. When the controller display reading falls below the alarm setpoints, return the
controller to normal operation.
10. Store the components of the calibration kit in a safe place.
Quarterly
Calibrate the combustible gas transmitter as described in “Calibration” on page 17 of this
manual.
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65-2405RK-04 Combustible Gas Transmitter • 13
Troubleshooting
The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the combustible gas transmitter.
NOTE: This troubleshooting guide describes transmitter problems only. See the
controller operator’s manual for problems you may encounter with the
controller.
Replacing Components of the Combustible Gas Transmitter
This section includes procedures to replace the combustible gas detector and amplifier.
Replacing the Combustible Gas Detector
NOTE: The combustible gas detector is installed on the junction box that does not house
the amplifier. This junction box was likely installed somewhere difficult to
access.
1. Turn off the controller.
2. Turn off or unplug power to the controller.
3. Unscrew the calibration cup/splash guard from the detector.
Table 2:Troubleshooting the Combustible Gas Transmitter
Condition Symptom(s) Probable Causes Recommended Action
Fail Condition • Controller indicates a
fail condition. • The detector-to- amplifier or amplifier-
to-controller wiring is
disconnected or
misconnected.
• The transmitter’s zero
reading is low enough
to cause a fail
condition.
• The transmitter is
malfunctioning.
1. Verify that the detector-to-amplifier
and amplifier-to-controller wiring is
correct and secure.
2. Calibrate the transmitter.
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
• Transmitterresponds
slowly or does not
respond to response
test.
• Unable to accurately
set the zero or
response reading
during calibration.
• Transmitter requires
frequent calibration.
Note: Under “normal”
circumstances, the
transmitter requires
calibration onceevery 3
months.
Some applications
may require a more
frequent calibration
schedule.
• Thecalibrationcylinder
is low, out-dated, or
defective.
• The calibration gas
flow rate is too low.
• The calibration gas is
not an appropriate
concentration.
• The transmitter is
malfunctioning.
• The flexible tubing to
the calibration cup/
splash guard has
become kinked,
blocked, or
disconnected.
1. Verify that the calibration cylinder
contains an adequate supply of a
fresh test sample.
2. Verify that the regulator used for
calibration is a 0.5 LPM regulator.
3. Verify that the calibration gas
concentration is appropriate for the
transmitter. The concentration should
be in the detection range, preferably
about half of the detection range.
4. Verify that the flexible tubing to the
calibration cup/splash guard is clear
and connected to the calibration cup/
splash guard.
5. If the calibration/response difficulties
continue, replace the detector.
6. If the calibration/response difficulties
continue, contact RKI for further
instruction.
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14 • 65-2405RK-04 Combustible Gas Transmitter
4. Remove the detector junction box’s cover from the junction box.
5. Disconnect the detector leads from the terminal block in the detector junction box.
Note the position of the color-coded leads as you remove them.
6. Unscrew the detector from the detector junction box.
7. Guide the detector leads of the replacement detector through the bottom conduit hub
of the detector junction box, then screw the mounting threads of the detector into the
conduit hub. If necessary for environmental conditions, apply thread sealant or teflon
tape to the hub and/or detector threads to seal them.
8. Connect the detector leads to the terminal block the same way the old detector was
wired (see Figure 3 on page 7).
9. Screw the calibration cup/splash guard onto the new detector.
10. Reinstall the detector junction box cover.
11. Turn on or plug in power to the controller.
12. Turn on the controller and place it into normal operation.
NOTE: When first powered up, the transmitter will enter about a one minute period
when the 4-20 mA output is stabilizing and may be above the controller alarm
points or well below zero momentarily. RKI controllers have a one minute
warmup period when the controller does not display any gas reading or give any
alarm indication. The combustible gas transmitter’s 4-20 mA signal should be
stable by the time the controller’s warmup period is over.
CAUTION: Allow the replacement detector to warm up for 5 minutes before you continue with
the next step.
13. Calibrate the transmitter as described in “Calibration” on page 17 of this manual.
Replacing the Amplifier
NOTE: The amplifier is not housed in the same junction box as the combustible gas
detector. The amplifier junction box should be somewhere accessible.
1. Turn off the controller.
2. Turn off or unplug power to the controller.
3. Remove the amplifier junction box’s cover from the junction box.
4. Unplug the detector terminal strip and controller terminal strip from their sockets.
You may leave the wires connected to the terminal strips.
5. Unscrew and remove the screw with the flat and lock washers that secures the
amplifier to the junction box.
6. Remove the old amplifier.
7. Place the new amplifier in the same position as the old amplifier. A foam gasket that
orients the amplifier and keeps it from rotating is installed on the bottom of the
amplifier. Make sure the amplifier is seated flat in the junction box.
8. Install the new amplifier into the junction box with the screw, lock washer, and flat
washer you removed in step 5 above.
9. Install the detector and controller terminals strips into their sockets on the new
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65-2405RK-04 Combustible Gas Transmitter • 15
amplifier as shown in Figure 4 on page 9 of this manual. If controller leads or detector
leads were removed during this procedure, refer to Table 3 and Table 4 below.
NOTE: When a transmitter is first powered up with a new amplifier, the initial output
may be either high or below zero depending on the setting of the zero pot. Be
sure to make arrangements so that this does not cause unwanted alarms.
10. Turn on power to the controller.
11. Turn on the controller and place it into normal operation.
NOTE: When first powered up, the transmitter will enter about a one minute period
when the 4-20 mA output is stabilizing and may be above the controller alarm
points or well below zero momentarily. RKI controllers have a one minute
warmup period when the controller does not display any gas reading or give any
alarm indication. The combustible gas transmitter’s 4-20 mA signal should be
stable by the time the controller’s warmup period is over.
12. Allow the transmitter to warm-up for 5 minutes.
13. Calibrate the transmitter as described in “Calibration” on page 17 of this manual.
Calibration Frequency
Although there is no particular calibration frequency that is correct for all applications, a
calibration frequency of every 3 to 6 months is adequate for most combustible gas
transmitter applications. Unless experience in a particular application dictates otherwise,
RKI Instruments, Inc. recommends a calibration frequency of every 3 months.
Table 3:Reconnecting the Amplifier
to the Controller
Amplifier Controller
Terminal Strip
Controller
Transmitter Terminal
Strip (typical)
PWR/SIG “-” - (DC -)
PWR/SIG “S” S (4 - 20 mA In)
PWR/SIG “+” + 24V
Table 4:Reconnecting the LEL
Detector to the Amplifier
Amplifier Detector
Terminal Strip Detector Lead
DETECTOR “R” RED
DETECTOR “W” WHT
DETECTOR “G” GREEN
DETECTOR “B” BLK
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16 • 65-2405RK-04 Combustible Gas Transmitter
If an application is not very demanding, for example detection in a clean, temperature
controlled environment where combustible gas is not normally present and calibration
adjustments are minimal at calibration, then a calibration frequency of every 6 months is
adequate.
If an application is very demanding, for example if combustible gas is present often and in
significant concentrations or the environment is not well controlled, then more frequent
calibration than every 3 months may be necessary. If potential catalyst poisons are known
or likely to be present, more frequent calibration than every 3 months will be necessary.
Determining Response Time
Since the detector junction box is installed remotely from the amplifier, the response time
of the detector will depend on the length of flexible tubing that is attached to the
calibration cup/splash guard. To determine the response time based on the length of
tubing connected:
1. Place the controller into its calibration mode or disable external alarms.
2. Note the current gas reading displayed at the controller.
3. Screw the regulator into the calibration cylinder. Do not use a zero air cylinder for this
operation.
4. Use the flexible tubing coming from the calibration cup/splash guard to connect the
regulator to the calibration cup.
5. Turn the regulator’s on/off knob counterclockwise to open the regulator. Gas will
begin to flow. Take note of the time or start a stopwatch.
6. When you first start to notice an increase in the gas reading, note how much time
passed between starting the gas flow and noticing a reading response.
7. Turn the regulator’s on/off knob clockwise to close the regulator.
8. Unscrew the regulator from the calibration cylinder.
9. Disconnect the calibration cup/splash guard’s flexible tubing from the regulator.
NOTE: Do not disconnect the flexible tubing from the calibration cup/splash guard.
10. Add 1 minute to the length of time determined in step 6. This is the response time for
the detector. When performing a response test, zero adjustment, or span adjustment,
gas must be applied for this length of time.
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