RKI Instruments 65-2395RK-CH4 Bedienungsanleitung

RKI Instruments, Inc.

www.rkiinstruments.com

65-2395RK-CH4

Methane Transmitter

Operator’s Manual

Part Number: 71-0183RK

Revision: A

Released: 4/12/11

65-2395RK-CH4 Methane 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 6 and 12 months, but can be

required more often or less often based on your usage.

65-2395RK-CH4 Methane 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

65-2395RK-CH4 Methane Transmitter

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Methane Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Mounting the Methane Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wiring the Methane Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Replacing Components of the Methane Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

65-2395RK-CH4 Methane Transmitter • 1

Overview

This manual describes the 65-2395RK-CH4 methane 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 methane transmitter.

Specifications

Table 1 lists specifications for the methane transmitter.

WARNING: When using the 65-2395RK-CH4, you must follow the instructions and

warnings in this manual to assure proper and safe operation of the

65-2395RK-CH4 and to minimize the risk of personal injury. Be sure to

maintain and periodically calibrate the 65-2395RK-CH4 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% volume

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)

2 • 65-2395RK-CH4 Methane Transmitter

Description

The 65-2395RK-CH4 methane transmitter is calibrated to methane. The transmitter

utilizes an infrared type of detector which has some advantages over a catalytic type of

combustible detector. The infrared detector will generally have a longer service life than a

catalytic detector, it will require calibration less often, and it can detect combustible gas

even if there is no oxygen in the sample which allows detection of combustible gas in an

inert atmosphere.

This section describes the components of the methane transmitter. The transmitter is a 4 -

20 mA type detector head. It consists of the methane detector, amplifier, and junction box.

Figure 1: Methane Transmitter Component Location

Infrared CH4 %Volume Detector

The infrared CH4 %Vol. detector is made up of a miniature infrared methane %Vol.

detector housed and encapsulated in a pipe nipple. The pipe nipple has 3/4” NPT threads

on each end and a 1 1/4” hex that allows removal or installation of the detector with a

wrench. A porous flame arrestor that is coated with a hydrophobic film that repels liquids

is on one end of the detector and allows sample gas to enter the detector. Four color coded

leads, red, white, green, and black, extend from the other end of the detector. The leads

allow you to connect the detector to the amplifier.

GWRB

LEL

57-1053RK

PWR/ SIG

S2 001

Amplifier

Controller Terminal

Strip

Detector Terminal Str

J-Box

IR CH4 % Volume Detector

Sensor

Current

mA SPAN

Jumper Pins,

actory Use Only

Factory Adjust Pot

Zero Pot

Span Pot

Factory Adjust Pot

ZERO

- Test Point

+ Test Point

65-2395RK-CH4 Methane Transmitter • 3

Amplifier

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 methane 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 IR %Vol. detector to

the amplifier.

NOTE: The IR %Vol. detector is factory-wired to the detector terminal strip. See “Wiring

the Methane Transmitter to a Controller” on page 5 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

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.

Junction Box

Use the junction box to install the transmitter at a mounting site that is remote from the

controller. The junction box protects the amplifier and wiring connections made to the

4 • 65-2395RK-CH4 Methane Transmitter

amplifier. Use the top 3/4’’ 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. 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 install a calibration cup

on the detector during calibration.

Installation

This section describes procedures to mount the methane transmitter in the monitoring

environment and wire the transmitter to a controller.

Mounting the Methane 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 lighter gases,

mount the detector near the ceiling; for heavier gases, mount the detector near the

floor.

Figure 2: Mounting the Methane Transmitter

.38

2.70

.75

Rubber

Spacers,

J-Box

3.65

3/4 NPT

Female

IR CH4 % Volume

Detector

7.10 MAX

65-2395RK-CH4 Methane Transmitter • 5

2. At the monitoring site you select, hang or mount the junction box with the detector

facing down (see Figure 2).

Wiring the Methane Transmitter 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 power to the controller.

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 3.

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 3).

• 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 methane 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.

11. Connect the wires to the applicable detector/transmitter terminal strip at the

controller as shown in Figure 3.

6 • 65-2395RK-CH4 Methane Transmitter

Figure 3: Wiring the Methane Transmitter to a Controller

12. 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.

Red

Cable Shield

Controller or

Recording Device

- (DC Ground)

4-20mAIn(S)

+ 24 VDC

Amplifier (Transmitter)

IR CH4 % Volume Detector

Detector Wires

Green

White

-Box

RW G

LEL PWR / SIG

Black

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