RKI Instruments 65-2405RK-04 Bedienungsanleitung

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

S2 001

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,

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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