RKI Instruments 65-2443SS User manual

RKI Instruments, Inc.
www.rkiinstruments.com
65-2443SS
PPM Hydrogen Transmitter
Operator’s Manual
Part Number: 71-0549
Revision: P1
Released: 3/4/21

2 • 65-2443SS PPM Hydrogen Transmitter
WARNING
Read and understand this instruction manual before operating detec-
tor. 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 frequen-
cies for most applications are between 6 and 12 months, but can be
required more often or less often based on your usage.

65-2443SS PPM Hydrogen Transmitter • 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 one year* from the 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. Parts must be returned to RKI Instruments, Inc. for repair or replacement. 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 instruction manual. This warranty indicates the full extend 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 only 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. Warranty
covers parts and labor performed at RKI Instruments, Inc. only, and does not cover field labor or
shipment of parts back to RKI.
a) Pump diaphragms and valves c) Batteries
b) Fuses d) Filter elements

4 • 65-2443SS PPM Hydrogen Transmitter
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PPM Hydrogen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mounting the PPM Hydrogen Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wiring the PPM Hydrogen Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmitter Burn-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing Components of the PPM Hydrogen Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Calibration Kit Humidifier Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Span Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

65-2443SS PPM Hydrogen Transmitter • 5
Overview
This manual describes the 65-2443SS ppm hydrogen 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
transmitter.
Specifications
Table 1 lists specifications for the ppm hydrogen transmitter.
WARNING: When using the 65-2443SS, you must follow the instructions and warnings in this
manual to assure proper and safe operation of the 65-2443SS and to minimize the risk
of personal injury. Be sure to maintain and periodically calibrate the 65-2443SS as
described in this manual.
Table 1:Specifications
Target Gas Hydrogen (H2)
Detection Range 0 - 2,000 ppm
Area Classification Explosionproof for Class I, Groups B, C, and D
Sampling Method Diffusion
Input Power 10 - 30 VDC
Signal Output 4 to 20 mA with impedance maximums listed below:
• 12 VDC input: 500 Ohms
• 24 VDC input: 1000 Ohms
Response Time 90% in 45 seconds

6 • 65-2443SS PPM Hydrogen Transmitter
Description
This section describes the ppm hydrogen transmitter’s components. It is a 4 to 20 mA type detector
head. It consists of the ppm hydrogen detector, amplifier, and junction box.
Figure 1: Component Location
PPM Hydrogen Detector
The ppm hydrogen detector is a MOS type (metal oxide semiconductor) detector packaged in a 1/2
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
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. Three color-
coded leads extend from the top of the detector. The leads allow you to connect the detector to the
amplifier.
The detector has a built in molecular sieve that only allows hydrogen to diffuse into the detector. The
output of the detector is non-linear and is linearized by the amplifier (see below).
J-Box
W
SPAN
DETECTOR
RB PW R / SIG
S
Reducing Bushing,
3/4 NPT to 1/2 NPT
Amplifier
Hydrogen Detector
Locking Set Screw
LINEAR

65-2443SS PPM Hydrogen Transmitter • 7
Amplifier
The amplifier converts the non-linear electrical output from the detector to a linear 4 to 20 mA signal
that corresponds to the detection range and transmits the signal to a gas monitoring controller. The
amplifier includes the terminal strips, span pot, linearizing pot, and test points.
Figure 2: Amplifier Component Location
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 transmitter to a controller.
Detector Terminal Strip
The detector terminal strip is a three position plug-in style terminal strip located below the controller
terminal strip. Use the detector terminal strip to connect the detector to the amplifier.
NOTE: The detector is factory-wired to the detector terminal strip. See page 10 for all wiring
procedures related to the transmitter.
Span Pot
The span pot is located to the left of the detector terminal strip (see Figure 2). Use a small flat blade
screwdriver to turn the span pot’s adjustment screw and adjust the amplifier’s full scale response
output during the calibration procedure.
Linearizing Pot
The linearizing pot (labeled LINEAR) is located in the bottom left corner of the amplifier (see
Figure 2). Use a small flat blade screwdriver to turn the linearizing pot’s adjustment screw while
applying mid-scale gas to linearize the transmitter’s output during the calibration procedure.
+ Test Point, Red
RBW
DETECTOR
- Test Point, Black
Mounting Screw
w/ flat and lock washer
SPAN
PWR / SIG
S
LINEAR
Factory Use Jumpers
Detector Terminal Strip
Span Pot
Controller Terminal Strip
Linearizing Pot

8 • 65-2443SS PPM Hydrogen Transmitter
Test Points
The test points are on the right side of the amplifier (see Figure 2). The test points produce a 100 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
on the bottom is the negative (-) test point and the red test point on the top is the positive (+) test point.
Junction Box
The stainless steel, corrosion resistant 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. An O-ring seals the interface between the junction box cover and the junction box base.
Use the cover on the front of the junction box to access the interior of the junction box. The detector
and amplifier are factory installed in the junction box. A locking set screw on the junction box cover
allows you to secure the junction box cover and prevent it from being removed.

65-2443SS PPM Hydrogen Transmitter • 9
Installation
This section describes procedures to mount the ppm hydrogen transmitter in the monitoring
environment and wire the transmitter to a controller.
Mounting the PPM Hydrogen Transmitter
Figure 3: Mounting the PPM Hydrogen Transmitter
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 transmitter 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 hydrogen, which is lighter than
air, mount the transmitter near the ceiling or where hydrogen is most likely to accumulate.
2. At the monitoring site you select, hang or mount the junction box with the detector facing down
(see Figure 3).
J-Box
.75
3/4 NPT
Female,
2X
3.66
3.15
2.40
.20 Dia. x .45
Slot, 2X
3.34
7.40 MAX
Hydrogen Detector
3/4 x 1/2 Reducing Bushing

10 • 65-2443SS PPM Hydrogen Transmitter
Wiring the PPM Hydrogen Transmitter
WARNING: Always verify that the power to the controller is off before you make wiring
connections.
1. Turn off power to the controller.
2. Place the controller’s power switch in the OFF position.
3. Remove the junction box cover.
4. The detector leads are factory wired. Verify that the detector leads are wired to the amplifier’s
detector terminal strip as shown in Figure 4.
5. 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.
6. Guide a three-conductor, shielded cable or three wires in conduit through the top conduit hub of
the junction box.
7. 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 transmitter. You will connect the opposite end of the cable’s drain wire to the
controller’s chassis (earth) ground.
8. Reinstall the controller terminal strip into its socket.
9. Secure the junction box cover to the junction box.
10. Route the cable or wires leading from the ppm hydrogen transmitter 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.