RKI 61-1000RK-05 User manual

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61-1000RK-05 / 61-0140RK-05
Combustible Gas Detector
Operator’s Manual
Part Number: 71-0087RK
Revision: F
Released: 10/26/18

61-1000RK-05/61-0140RK-05 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.
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.

61-1000RK-05/61-0140RK-05 Combustible Gas Detector
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-05/61-0140RK-05 Combustible Gas Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
61-0140RK-05 Combustible Gas Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting the Combustible Gas Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring the Combustible Gas Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacing the Combustible Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

61-1000RK-05/61-0140RK-05 Combustible Gas Detector • 5
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.
The 61-1000RK-05 combustible gas detector includes the 61-0140RK-05 combustible gas
detector and a junction box. This manual may also be used for the 61-0140RK-05
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 61-0140RK-05 combustible gas
detector, disregard all references to the junction box and junction box terminal strip.
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:
WARNING: When using the 61-1000RK-05, you must follow the instructions and
warnings in this manual to assure proper and safe operation of the
61-1000RK-05 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 61-1000RK-05 as described in this
manual.
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
Accuracy ± 5% of reading or ± 2% LEL (whichever is greater)
!

6 • 61-1000RK-05/61-0140RK-05 Combustible Gas Detector
Description
This section describes the components of the 61-0140RK-05 and 61-1000RK-05 detectors.
The 61-1000RK-05 includes the 61-0140RK-05 combustible gas detector and a junction box.
A four point terminal strip is provided inside the junction box for detector connections.
The 61-0140RK-05 does not include a junction box.
Figure 1: 61-1000RK-05 Component Location
61-0140RK-05 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 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. The controller conduit hubs are normally 3/4 NPT, so a 3/4 x 1/2
NPT reducer may be necessary to install the combustible gas detector. A flame arrestor
guard is located at the bottom of the detector and is permanently bonded to the detector
housing. The flame arrestor guard protects the flame arrestor from impact damage. Four
color-coded leads extend from the top of the detector. The leads allow you to connect the
detector to the terminal block.
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 ensure that there is enough room to installa
calibration cup on the detector during calibration.
The bottom conduit hub includes a 3/4 x 1/2 NPT reducer that allows you to screw the
detector into the hub. The terminal block within the junction box facilitates the wiring
Rubber
Spacer,
3X
Red
J-Box
Green
Black
White

61-1000RK-05/61-0140RK-05 Combustible Gas Detector • 7
process. A cover on the front of the junction box allows access to the interior of the
junction box.
Installation
This section describes procedures to mount the combustible gas detector in the
monitoring environment and wire the detector to a controller.
NOTE: The 61-0140RK-05 detector retains its explosion proof classification only when
installed in the explosion proof junction box. The detector is not explosion proof
if installed in a controller conduit hub.
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 2: Mounting the Combustible Gas Detector
0.382.70
J-Box
.75
3/4 x 1/2NPT
Reducing Bushing
Combustible
Detector
3/4 NPT
Female
3.65
7.50 max Spacer, 3X

8 • 61-1000RK-05/61-0140RK-05 Combustible Gas Detector
2. At the mounting site you select, hang or mount the junction box with the detector
facing down (see Figure 2).
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 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 10. See Figure 3, the controller operator’s manual, and
the controller’s detector head specification sheet for the 61-0140RK-05 detector for the
wiring connections.
4. Remove the junction box cover.
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.
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.
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.
7. Secure the junction box cover to the junction box.
8. Route the cable or wires leading from the combustible gas detector through one of the
conduit hubs at the controller housing. Use appropriate conduit fittings and
construction technique for the environmental rating of the controller. RKI controllers
are typically rated NEMA 4X.
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
61-1000RK-05 detector.
10. If using 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.

61-1000RK-05/61-0140RK-05 Combustible Gas Detector • 9
Figure 3: Wiring the Combustible Gas Detector to a Controller
Green
White
Red Controller
LEL
Detector
Terminals
J-Box
Terminal Strip
Black
Detector Wires
Red
Green
White
Combustible
Detector
Black
Cable Shield

10 • 61-1000RK-05/61-0140RK-05 Combustible Gas Detector
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 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.
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
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.
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 and of normal oxygen concentration, 20.9%).
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 operator’s manual for
directions.