RKI Instruments 65-2445 Series User manual

RKI Instruments, Inc.
www.rkiinstruments.com
65-2445-XX
PPM Hydrogen Transmitter
Operator’s Manual
Part Number: 71-0609
Revision: 0
Released: 5/8/23

2• 65-2445-XX PPM Hydrogen Transmitter Operator’s Manual
WARNING
Read and understand this instruction manual before operating
instrument. Improper use of the gas monitor could result in bodily
harm or death.
Periodic calibration and maintenance of the gas monitor is essential
for proper operation and correct readings. Please calibrate and
maintain this instrument regularly! Frequency of calibration depends
upon the type of use you have and the sensor types. For most
applications, typical calibration frequencies are between 3 and 6
months but can be more often or less often based on your usage.

65-2445-XX PPM Hydrogen Transmitter Operator’s Manual • 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:
• 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 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 APARTI CULAR 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 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.

4• 65-2445-XX PPM Hydrogen Transmitter Operator’s Manual
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PPM Hydrogen Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Calibration Kit Humidifier Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting the Span Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the Linearization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

65-2445-XX PPM Hydrogen Transmitter Overview • 5
Overview
This manual describes the 65-2445-XX 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 65-2445-XX, you must follow the instructions and warnings in
this manual to assure proper and safe operation of the 65-2445-XX and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 65-2445-XX as described in this manual.
Table 1: Specifications
Target Gas Hydrogen (H2)
Detection Range • 65-2445-100: 0 - 100 ppm
• 65-2445-500: 0 - 500 ppm
• 65-2445-1000: 0 - 1,000 ppm
• 65-2445-2000: 0 - 2,000 ppm
Area Classification Explosion-proof 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• Description 65-2445-XX 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
Amplifier
J-Box
Hydrogen Detector
LINEAR
Reducing Bushing,
3/4 NPT to 1/2 NPT
COARSE
FIN E
DETECTOR PWR / SIG
SW B R

65-2445-XX PPM Hydrogen Transmitter Description • 7
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).
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, coarse span pot, fine 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.
Mounting Screw
w/ flat and lock washer
-TestPoint,Black
DETECTOR
WBR
+ Test Point, Red
Detector Terminal Strip
Controller Terminal Strip
COARSE
PWR/ SIG
S
FINE
Coarse
Span Pot
Linearizing Pot
Fine Span
Pot
LINEAR

8• Description 65-2445-XX PPM Hydrogen Transmitter
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.
Coarse Span Pot
The coarse span pot (labeled COARSE) is located to the left of the detector terminal strip and
below the fine span pot (see Figure 2). Use a small flat blade screwdriver to turn the span pot’s
adjustment screw and adjust the amplifier’s coarse full scale response output during the
calibration procedure.
Fine Span Pot
The fine span pot (labeled FINE) is located to the left of the detector terminal strip and above the
coarse span pot (see Figure 2). Use a small flat blade screwdriver to turn the span pot’s adjustment
screw and adjust the amplifier’s fine 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 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
Use the junction box to install the transmitter at a mounting site that is remote from the controller.
The junction box also protects the amplifier and wiring connections made to the amplifier. Use the
top 3/4 NPT conduit hub to connect wiring from the amplifier to the controller. 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.

65-2445-XX PPM Hydrogen Transmitter Installation • 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).
.38
.75
2.70
JBox
Rubber
Spacers,
3X
3/4 NPT Female
3.65
Hydrogen
Detector
3/4 x 1/2 Reducing
Bushing
7.5 max

10 • Installation 65-2445-XX 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.