Macurco RD-6 User Manual

Macurco™ RD-6 Refrigerant Detector, Controller and Transducer User Instructions

Important: Keep these User Instructions for reference

TABLE OF CONTENTS

GENERAL SAFETY INFORMATION 4

List of Warnings and Cautions 4 USE INSTRUCTIONS AND LIMITATIONS 5 Use For 5 Do Not Use For 5 General Description 5

INSTALLATION AND OPERATING INSTRUCTIONS 6

MAINTENANCE 15

Sensor Life Reset 16

MACURCO GAS DETECTION PRODUCTS WARRANTY 24

Intended Use 4

Features 6 Specifications 6

Location 7 Installation 7 4-20 mA Output diagram 8

DVP-120 Control Panel diagram 10

Power Up 11 Operation 11 Default – Factory Settings 11

On-board Diagnostics 14 Sensor Poisons 15

End-of-Life Signal 15

Cleaning 16 Testing 16

Garage diagram 8 Multiple Device diagram 9 Alarm Control Panel diagram 9

Alternate Alarm Panel 11

Power-up Test setting 12 Display setting 12 Buzzer setting 12 Alarm Relay setting 13 Alarm Relay Configuration 13 Fan Relay setting 13 Fan Relay Delay setting 14 Fan Relay Minimum Runtime setting 14 Fan Relay Latching setting 14 Trouble Fan Setting 14 4-20mA Output setting 14

Operation Test 17 Manual Operation Test 18 Refrigerant Gas Test 18

Quick Gas Test 22

GENERAL SAFETY INFORMATION Intended Use

The Macurco RD-6 is a low voltage, dual relay Refrigerant (REF) detector, controller and transducer. The RD-6 has selectable 4-20 mA output, buzzer and digital display options. It is an electronic detection system used to measure the concentration of refrigerant gas and provide feedback and automatic exhaust fan control to help reduce refrigerant gas concentrations in industrial refrigeration, cold storage, warehouses, hockey rinks or other commercial applications. The RD-6 is a low level meter capable of detecting several refrigerants including R-22, R-134A, R-404A, R-407C and R-410A, and displaying from 0-1,000 ppm of refrigerant gas. The RD-6 is factory calibrated and 100% tested for proper operation.

List of Warnings and Cautions within these User Instructions

! WARNING

 Each person using this equipment must read and understand the information in these User Instructions before use. Use of this

equipment by untrained or unqualified persons, or use that is not in accordance with these User Instructions, may adversely affect product performance and result in sickness or death.

 Use only for monitoring the gas which the sensor and instrument are designed to monitor. Failure to do so may result in exposures

to gases not detectable and cause sickness or death. For proper use, see supervisor or User Instructions, or call Technical Service at 1-877-367-7891.

 This equipment may not function effectively below 0F or above 125F (-18C or above 52C). Using the detector outside of this

temperature range may adversely affect product performance and result in sickness or death.

 This detector helps monitor for the presence and concentration level of a certain specified airborne gas. Misuse may produce an

inaccurate reading, which means that higher levels of the gas being monitored may be present and could result in overexposure and cause sickness or death. For proper use, see supervisor or User Instructions, or call Technical Service at 1-877-367-7891.

 High voltage terminals (120/240 VAC) are located within this detector, presenting a hazard to service technicians. Only qualified

technicians should open the detector case and service the internal circuits. Ensure power is removed from the detector relays prior to servicing the unit. Failure to do so may result in sickness or death.

 Do not disassemble unit or attempt to repair or modify any component of this instrument. This instrument contains no user

serviceable parts, and substitution of components may impair product performance and result in sickness or death.

 Using a certified gas with a concentration other than the one listed for this detector when conducting a calibration or calibration

verification test (bump test) will produce inaccurate readings. This means that higher levels of the gas being monitored may be present and could result in overexposure and cause sickness or death. For proper use, see supervisor or User Instructions, or call Technical Service at 1-877-367-7891

 The following steps must be performed when conducting a calibration verification test (bump test) to ensure proper performance of

the monitor. Failure to do so may adversely affect product performance and result in sickness or death.  When performing a calibration verification test (bump test) only use certified calibration gas at the required concentration level.

Do not test with expired calibration gas.

 If the instrument cannot be tested, do not use until the reason can be determined and corrected.  Do not cover or obstruct display or visual alarm cover.  Ensure sensor inlets are unobstructed and free of debris

USE INSTRUCTIONS AND LIMITATIONS

! WARNING

Each person using this equipment must read and understand the information in these User Instructions before use. Use of this equipment by untrained or unqualified persons, or use that is not in accordance with these User Instructions, may adversely affect product performance and result in sickness or death.

Use For

The RD-6 provides refrigerant gas detection and automatic exhaust fan control for industrial refrigeration, cold storage, warehouses or other commercial applications. The RD-6 is capable of detecting several refrigerants including R-22, R-134A, R-404A, R-407C and R410A. Refrigerants are colorless and nearly odorless liquids or gases divided into two groups according to toxicity and flammability. See ANSI/ASHRAE Standard 34-2007 - Designation and Safety Classification of Refrigerants for details. Always review the refrigerant MSDS and safety classifications before use. RD-6 can be used stand alone, with the Macurco DVP-120 Detection and Ventilation Control Panel, other 12 VAC or 24 VDC fire/security panels or building automation systems.

! WARNING

Use only for monitoring the gas which the sensor and instrument are designed to monitor. Failure to do so may result in exposures to gases not detectable and cause sickness or death. For proper use, see supervisor or User Instructions, or call Technical Service at 1877-367-7891.

Do Not Use For

The RD-6 is not intended for use in hazardous locations. Do not mount the RD-6 where the normal ambient temperature is below 0°F or exceeds 125°F (below -18C or above 52C). The RD-6 mounts on a 4x4 electrical box supplied by the contractor. Do not install the RD-6 inside another box unless it has good air flow through it.

! WARNING

This equipment may not function effectively below 0F or above 125F (-18C or above 52C). Using the detector outside of this temperature range may adversely affect product performance and result in sickness or death.

General Description

The RD-6 is a low voltage, dual relay refrigerant gas detector and automatic ventilation controller. The RD-6 uses a microcomputer controlled, electronic system to measure the concentration of refrigerant gas, actuate relays and provide a 4-20mA output. The RD-6 has a long life solid-state sensor (expected life of 7+ years). The RD-6 is a low level meter capable of displaying from 0-1,000ppm of refrigerant gas.

Features

 ETL Listed to UL 61010-1 and CAN/CSA C22.2 No 61010-1  Low level meter capable of displaying from 0-1,000 ppm refrigerant gas  Selectable fan and alarm relay activation  5 A SPDT fan relay controls starters of exhaust fans  0.5 A N.O. or N.C. alarm relay connects to warning devices or control panels  4-20 mA Current Loop  RD-6 mounts on a standard 4x4 electrical box and becomes cover for the box  Supervised system: any internal detector problem will cause the fan & alarm relay to activate  Calibration verification test kit is available. One screw allows access for calibration or gas test

Specifications

 Power: 3 W (max) from 12 to 24 VAC or 12 to 32 VDC  Current @ 24 VDC: 75 mA in alarm (two relays), 50 mA (fan relay only) and 23 mA stand by  Shipping Weight: 1 pound (0.45 kg)  Size: 4 1/2 x 4 x 2 1/8 in. (11.4 X 10.2 X 5.4 cm)  Color: Dark gray  Connections: plugs/terminals  Mounting box: (not included) 4x4 electric  Fan relay: 5 A, 240 VAC, pilot duty, SPDT, latching or non-latching  Fan relay actuation: selectable at diS (disable), 100 (default), 150, 200, 250, 300, 350ppm  Fan Delay Settings of 0, 1, 3 (default), 5 and 10 minutes  Fan Relay Minimum Runtime settings are 0 (default), 3, 5, 10 or 15 minutes  Fan relay latching or not latching (default) selectable  Alarm relay: 0.5A 120 V, 60 VA  Alarm relay actuation: selectable N.O. (default) or N.C.  Alarm relay settings: diS, 100, 150, 200, 250, 300 (default), 350, 400, 450, 500, 550 or 600ppm  Current Loop: 4-20 mA for 0-1,000 ppm refrigerant gas, selectable to off or on (default)  Buzzer: 85 dBA at 10cm settable to on (default) or off  Digital display: 3 digit LED selectable to on (default) or off  Operating environ: 0°F to 125°F (-18C to 52C).10 to 90% RH non-condensing

INSTALLATION AND OPERATING INSTRUCTIONS

The following instructions are intended to serve as a guideline for the use of the Macurco RD-6 Refrigerant Detector. It is not to be considered all-inclusive, nor is it intended to replace the policy and procedures for each facility. If you have any doubts about the applicability of the equipment to your situation, consult an industrial hygienist or call Technical Service at 1-877-367-7891.

! WARNING

This detector helps monitor for the presence and concentration level of a certain specified airborne gas. Misuse may produce an inaccurate reading, which means that higher levels of the gas being monitored may be present and could result in overexposure and

cause sickness or death. For proper use, see supervisor or User Instructions, or call Technical Service at 1-877-367-7891.

Location

A RD-6 is normally mounted low in the room on a wall or column one foot above the floor in a central area where air movement is generally good. Use the same spacing as for smoke detectors, 30-foot centers, 900 square feet per detector (84 sq. meters). The coverage depends on air movement within the room or facility. Extra detectors may be needed near any areas where people work or where the air is stagnant. The RD-6 mounts on a 4x4 electrical box supplied by the contractor. Do not install the RD-6 inside another box unless it has good air flow through it. Do NOT mount the RD-6 where the normal ambient temperature is below 0°F or exceeds 125°F (below -18°C or above 52°C).

! WARNING

High voltage terminals (120/240 VAC) are located within this detector, presenting a hazard to service technicians. Only qualified technicians should open the detector case and service the internal circuits. Ensure power is removed from the detector relays prior to servicing the unit. Failure to do so may result in sickness or death.

Installation

1. The RD-6 mounts on a 4” square (or 4x4) electrical box supplied by the contractor. Do not mount the RD-6 inside another box, unless it has good air flow through it.

2. Connect the RD-6 to Class 2 power supply only. It is suggested to use a separate transformer for powering the unit or units because of possible interference’s from other devices on the same power supply.

3. Connect the RD-6 to the control cables with terminal plugs. When making connections, make sure the power is off.

4. There are two terminals for Power: 12 to 24 VAC or 12 to 32 VDC, with no polarity preference.

5. There are two terminals for the dry alarm relay contacts, again with no polarity preference. The alarm relay can switch up to 0.5 A 120 V, or 60 VA. The alarm relay is activated if gas reaches or exceeds the alarm settings. See OPERATION section of these User Instructions for details on relay settings.

6. The alarm relay can be configured to normally open (default) (N.O.) or normally closed (N.C.) and will activate if the gas concentration exceeds alarm set point. It will deactivate once the gas concentration drops below the alarm set point. Note that the “disable” setting will cause the alarm relay not to engage at all.

7. The dry contact, SPDT fan relay has three terminals. The common (COM.), normally open (N.O.) and the normally closed (N.C.) contact. The fan relay can switch up to 5.0 A up to 240 VAC. See OPERATION section of these User Instructions for details on relay settings.

8. The Fan Relay can be configured for latching or non-latching (default) when activated (when the gas concentration exceeds fan relay set point). Once latched in, power will need to be interrupted or the “TEST” button pressed to un-latch the relay condition.

9. The Fan Relay will engage if the fan setting refrigerant concentration is exceeded for longer than the Fan Relay Delay time. Unless it is configured for latching, the fan relay will disengage once both of these conditions have been met:

 Refrigerant gas concentration has dropped below fan setting  Fan Relay Run time has been exceeded

Note that the “disable” fan setting will cause the fan relay to not engage. The fan relay will engage in trouble fault condition (if the Trouble Fan Setting Option is set to “On”) and will disengage once trouble fault condition is cleared.

10. The Current Loop is 4 mA in clean air and 20 mA for 1,000 ppm refrigerant gas

In this application (above) the Fan or primary relay is used as a low level alarm relay. The Alarm or secondary relay is used as a supervisory relay when utilized in the normally closed configuration. The RD-6 monitors all critical functions of the unit through software diagnostics that continually test and verify its operations. If a problem is found, the unit will switch to a fail-safe/error mode or trouble condition. In this error mode the Fan* and Alarm relays will be activated indicating the trouble condition at panel and the RD-6 display will flash the error. *See the Trouble Fan Setting Option.

Power Up

The RD-6 steps through an internal self-test cycle for the first minute that it is powered. The unit will execute the test cycle any time power is dropped and reapplied (i.e. power failure). During the self-test cycle the unit will display the firmware version number, then count down from 60 to 0 (if the display option is “on”) and finally go into normal operation. The alarm relay will be activated for 10 seconds and the fan relay for 60 seconds during the power-up cycle unless the “Power Up Test” (PUt) option is OFF. The indicator light (LED) will flash green during the self-test cycle. At the end of the 1 minute cycle, the unit will take its first sample of the air and the indicator light will turn solid green.

Operation

1. With the display function turned “On”, the RD-6 will show the current concentration of refrigerant gas ppm or “0” (zero) in clean air. When the gas concentration reaches the Fan Relay setting (100 ppm, for example) the display will flash back and forth between “FAn” and “100”. With the display function turned ”OFF”, the display does not show the refrigerant gas concentration, but will show “FAn” as long as the fan relay is activated.

2. With the display function turned “On” and the refrigerant gas concentration reaching the Alarm Relay setting, (200 ppm, for example) the display will flash back and forth between “ALr” and “200”. The buzzer will sound indicating “Alarm” if the buzzer is turned “On”. With the display function turned off the display does not show the refrigerant gas concentration, but will show “ALr” when the Alarm relay is activated.

3. With the 4-20 mA function turned “On” and the refrigerant gas concentration climbing, the 4-20 mA signal will ramp up corresponding to the concentration (0-300 ppm, for example). The display will show “FAn” and “ALr” and sound as outlined above.

Default Configuration – Factory Settings

The default Power Up Test setting is ON



The default Display setting is ON

 The default Buzzer setting is ON  The default Alarm Relay Setting is activation at 300 ppm  The default Alarm Relay Configuration setting is Normally Open  The default Fan Relay Setting is activation at 100 ppm  The default Fan Relay Delay setting is 3 minutes  The default Fan Relay Minimum Runtime setting is 0 minutes  The default Fan Relay Latching condition is OFF  The default Trouble Fan Setting condition is OFF  The default 4-20mA Output setting is ON

To change settings, remove the Philips screw on the front of the RD-6. Pull off the front cover of the unit.

Selecting Default Configuration – “dEF”

To select the Default Configuration, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The first selection is the “dEF” or Default setting. Push Enter. If it is already in Default configuration, there will be no action. If it is not already in Default configuration, “nO” will be displayed. Push Next to change it to “yES” (flashing) then push Enter to confirm the change (solid) and push Enter again to return to “dEF” in the con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Power Up Test Option – “PUt”

To select the Power Up Test Configuration, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. Then push the Next button to get to the second selection “PUt” or Power Up Test setting. Push Enter. If the test is “On” push Next to turn it “OFF” (flashing) then push Enter to confirm the change (solid) and push

Enter again to return to “PUt” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Display Option – “dSP”

To select the Display Configuration, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. Then push the Next button to get to the third selection “dSP” or Display setting. Push Enter. If

the display is “On” push Next to turn it “OFF” (flashing) then push Enter to confirm the change (solid) and push Enter again to return to “dSP” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Buzzer Option – “bUZ”

To select the Buzzer Configuration, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The fourth selection is the “bUZ” or Buzzer setting. Push Next twice to get to “bUZ” then Enter. If the display is “On” push Next to turn it “OFF” (flashing) then push Enter to confirm the change (solid) and push Enter again to return to “bUZ” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Alarm Relay Setting – “ArS”

To select the Alarm Relay Setting, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the

Enter button to enter the Con menu. The fifth selection is the “ArS” or Alarm Relay Setting. Push Next three times to get to “ArS” then Enter. If the display is “diS” (disabled) push Next to change it to 100, 150, 200, 250, 300 (default), 350, 400, 450, 500, 550 or 600ppm

(flashing) then push Enter to confirm the change (solid) and push Enter again to return to “ArS” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Alarm Relay Configuration – “Arc”

To select the Alarm Relay Configuration, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The sixth selection is the “Arc” or Alarm Relay Configuration. Push Next four times to get to “Arc” then Enter. If the relay is “nO” (normally open) push Next to turn it to “nC” (flashing) then push Enter to confirm the change (solid) and push Enter again to return to “Arc” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Fan Relay Settings – “FrS”

To select the Fan Relay setting, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The seventh selection is the “FrS” or Fan Relay setting. Push Next five times to get to “FrS” then

Enter. If the fan relay is “diS” (disabled) push Next to change it to 100 (default), 150, 200, 250, 300, 350 ppm (flashing) then push Enter to confirm the change (solid) and push Enter again to return to “FrS” in the Con menu. Push Next until “End” is displayed then

push Enter to get back to normal operation.

Selecting Fan Relay Delay – “Frd”

To select the Fan Relay Delay setting, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The eighth selection is the “Frd” or Fan Relay Delay. Push Next six times to get to “Frd” then Enter. If the delay is “0” (zero minutes) push Next to change it to 1, 3, 5, or 10 minutes (flashing) then push Enter to confirm the

change (solid) and push Enter again to return to “Frd” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Fan Relay Minimum Runtime – “Frr”

To select the Fan Relay Minimum Runtime setting, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The ninth selection is the “Frr” or Fan Relay Minimum Runtime. Push Next seven times to get to “Frr” then Enter. If the runtime is “0” (zero minutes) push Next to change it to 3, 5, 10 or 15 minutes (flashing) then push Enter to confirm the change (solid) and push Enter again to return to “Frr” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Fan Relay Latching Option – “FrL”

To select the Fan Relay Latching Option, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The tenth selection is the “FrL” or Fan Relay Latching Option. Push Next nine times to get to “FrL” then Enter. If latching is “OFF” push Next to turn it to “On” (flashing) then push Enter to confirm the change (solid) and push

Enter again to return to “FrL” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting Trouble Fan Setting Option – “tFS”

To select the Trouble Fan Setting Option, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The eleventh selection is the “tFS” or Trouble Fan Setting Option. Push Next ten times to get to “tFS” then Enter. If Trouble Fan Setting is “OFF” push Next to turn it to “On” (flashing) then push Enter to confirm the change (solid) and push Enter again to return to “tFS” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

Selecting 4-20mA Output Option – “420”

To select the 4-20mA Output Option, in normal mode, push the Next button to get to “Con” or the Configuration menu. Then push the Enter button to enter the Con menu. The twelfth selection is the “420” or 4-20mA Output Option. Push Next eleven times to get to “420” then Enter. If the 4-20mA is “On” push Next to turn it to “OFF” (flashing) then push Enter to confirm the change (solid) and push Enter again to return to “420” in the Con menu. Push Next until “End” is displayed then push Enter to get back to normal operation.

On-board Diagnostics

The RD-6 monitors all critical functions of the unit through software diagnostics that continuously test and verify unit operations. If a problem is found, the unit will switch to a fail-safe/error mode or trouble condition. In this error mode, the Alarm relay will be activated, the 4-20 mA current loop will go to 24 mA, the unit will display the error code, the green status indicator LED light will flash and the buzzer will chirp intermittently. The Fan relay will also engage if the Trouble Fan Setting Option is set to “On”. This is a safety precaution. To clear this mode, simply turn off power to the unit for a few seconds, or push the ENTER/TEST switch (inside the unit). This will cause the unit to restart the 1 minute self-test cycle.

The 4-20 mA signal can be used for troubleshooting:

 0 mA is most likely a connection problem

 4-20 mA is normal gas reading range (0-1,000 ppm)

 24 mA indicates a Trouble condition

Error Codes

 t01 Sensor missing

 t02 Temperature compensation failure

 t04 EEPROM bad checksum

 t10 Bad EEPROM

 t20 Bad calibration

 t40 Factory calibration failure

 t80 Read ADC failure

 t100 Under range

 t200 Sensor warranty expired

Note: For trouble codes over 080 the display will alternate between t_1 and t00 for t100 and between t_2 and t00 for t200.

If the error mode repeats frequently, check for continuous power and proper voltage. If power is not the problem and a unit has repeating error conditions, it may need to be returned to Macurco for service, per these User Instructions.

Sensor Poisons

The gas sensor in the detector is designed with extreme sensitivity to the environment. Alcohols, ammonia, cleaning solvents, paint thinner, gasoline vapors, and aerosol propellants may cause nuisance alarms.

In addition, the sensing function may be deteriorated if it is exposed to a direct spray from aerosols such as paints, silicone vapors, etc., or to a high density of corrosive gases (such as hydrogen sulfide or sulfur dioxide) for an extended period of time.

MAINTENANCE

The RD-6 is low maintenance. The unit uses a long life solid-state sensor that has a 7+ year life expectancy (in normal conditions). The detector’s performance should be tested regularly by using gas as detailed in the Gas Testing section. All maintenance and repair of products manufactured by Macurco are to be performed at the appropriate Macurco manufacturing facility. Macurco does not sanction any third-party repair facilities. Note: There is no field calibration procedure for the Macurco RD-6.

End-of-Life Signal

The RD-6 has a long life, non-replaceable solid-state sensor. Seven (7) years after the RD-6 is installed the sensor end-of-life signal will be activated indicating that the RD-6 has reached the end of its typical usable life. The end-of-life signal will cause an error code t200 “Sensor expired”. See Error Codes section. The end-of-life signal can be silenced for 48 hours by pressing the "ENTER/TEST" button or by temporarily dropping power to the unit. The end-of-life signal provides the user an opportunity to test the sensor assuring that it is still performing within acceptable parameters though the sensor is nearing the end of its expected life. The silence function will continue to be available for 29 days after the RD-6 initiates the initial end-of-life signal. After this 29 day period the RD-6 can no longer be silenced and the sensor life must be reset or the RD-6 detector replaced.

Sensor Life Reset

1. Remove the Philips screw on the front of the RD-6. Pull the front cover of the unit off.

2. To reset the sensor life (rSt), from normal or warm-up mode, press the Next button four times to get to “SEn” or Sensor Mode.

3. Then press the Enter button to get to “rSt” - Reset Sensor Mode.

4. Press the Enter button again to see the sensor reset status. If the sensor life has already been reset, done “don” will be displayed. If it has not already been reset, “nO” will be displayed. Push Next to change it to “ yES” (flashing) then push Enter to confirm the change (solid) and push Enter again to return to "rSt” in the “SEn” menu. Push Next until “End” is displayed then push Enter to get back to normal operation. Note: The sensor life will be reset for 1 year.

Note: If the sensor is reset and the detector not replaced, it is necessary to test the sensor to assure that it is still performing within acceptable specifications though the sensor is nearing the end of its expected life. There will be no other indication of sensor performance.

! WARNING

Do not disassemble unit or attempt to repair or modify any component of this instrument. This instrument contains no user serviceable parts, and substitution of components may impair product performance and result in sickness or death.

CAUTION

Avoid the use of harsh cleaning materials, abrasives and other organic solvents. Such materials may permanently scratch the surfaces and damage the display window, labels, sensor or instrument housing. High voltage terminals (100-240VAC) are located within this detector, presenting a hazard to service technicians. Only qualified technicians should open the detector case and service the internal circuits. Ensure power is removed from the detector prior to cleaning the unit. Failure to do so may result in sickness or death.

Cleaning

Cleaning of the external surfaces is best carried out using a damp cloth with a mild detergent or soap. Use a vacuum cleaner with soft brush to remove dust or contamination under the cover. Do not blow out the sensor with compressed air.

TESTING

! WARNING

Using a certified gas with a concentration other than the one listed for this detector when conducting a calibration or calibration verification test (bump test) will produce inaccurate readings. This means that higher levels of the gas being monitored may be present and could result in overexposure and cause sickness or death. For proper use, see supervisor or User Instructions, or call Technical Service at 1-877-367-7891.

General

All RD-6 units are factory calibrated and 100% tested for proper operation. During normal operation the green status indicator LED light will be on steady, the fan & alarm relay will be in standby mode and the 4-20 mA output will be at 4mA (in clean air).The unit also performs a regular automatic self-test during normal operation. If the unit detects an improper voltage or inoperable component, it will default into Error mode. In this error mode, the Alarm relay will be activated, the 4-20 mA current loop will go to 24 mA, the unit will display the error code, the green status indicator LED light will flash and the buzzer will chirp intermittently. The Fan relay will also engage if the Trouble Fan Setting Option is set to “On”.

Operation Test

Check that the green RD-6 status indicator LED light is illuminated continuously. If not, do not proceed with the tests. If the unit is in error mode contact your local representative or Macurco technical service representative for information on resolving the problem.

1. Remove the single screw in the middle of the front cover of the RD-6.

2. Remove the front cover.

3. Observe the LED light on the front of the RD-6.

4. If the light is solid green proceed to step 6.

5. If the green status indicator LED light is off or flashing, refer to the General section above.

6. Locate the switch labeled ENTER/TEST on the left side of the printed circuit board. Press the Test switch once.

7. The RD-6 will step through a cycle test:

a. The display progresses through the BUZ (Buzzer Test) Art (alarm relay test), Frt (fan relay test) then 42t (4-20 mA output

test). Make sure that the settings are “On” or not disabled “diS”. b. During the first 10 seconds of the test cycle, the display will show BUZ and set off the audible buzzer c. The alarm relay will be closed, so any devices connected to that relay will be tested. d. The Fan relay will be activated for the next 1 minute of the test, so if the fan circuits are wired in the normal manner, the fan

should run. e. The 4-20mA output will then ramp up from 4 to 16 mA over the next 130 seconds of the test, so if the circuit is wired in the

normal manner, the control panel or building automation system should respond. f. At the end of the test cycle, the light will turn green and be on steady (Normal Operation), the fan & alarm relay will be in

standby mode and the 4-20 mA output will return to 4 mA (in clean air).

8. When testing is completed reassemble the unit or units.

Manual Operation Test

This option gives the user the opportunity to manually initiate an individual test for each relay, the analog output and the sensor response to gas. From normal operation mode press the Next button 2 times to get to the Test Mode (tSt). Press the Enter button once to get into the Test Menu. Press the Next button to scroll through the five test options and press Enter to initiate the selected test. Note that if the relay or 4–20 mA output has been disabled, the test selection will not be displayed in the test menu.

bUZ – Buzzer Test, 3 seconds

Art - Alarm Relay Test, 5 seconds

Frt - Fan Relay Test, 60 seconds

42t - 420 loop test, 130 seconds

gtS - Gas Test, 3 minutes (no output to the panel during the gas test)

The display will flash during the test, or in the case of the gas test, the gas level will alternate with gtS. Once the test is complete, the display will return to steady display. To exit the test menu, press the Next button until “End” is displayed then press Enter to return to normal mode.

Refrigerant Gas Test

! WARNING

The following steps must be performed when conducting a calibration verification test (bump test) to ensure proper performance of the monitor. Failure to do so may adversely affect product performance and result in sickness or death.

 When performing a calibration verification test (bump test) only use certified calibration gas at the required concentration level.

Do not test with expired calibration gas.

General

The RD-6 calibration can be verified or bump-tested with the RD-FTK with R-134a refrigerant gas, regulator and test hood, available through your local representative or from Macurco.

Note: For optimum test results it is suggested that the unit be in clean air (green light on steady) and be in a low ambient air flow. Contents of the FTK

 RD-FTK: (1) Gas Cylinder, 300 ppm R-134a refrigerant gas in air  Gas regulator with about two feet of plastic tubing  Humidifier  Test hood

FTK Information

Several detectors can be tested with one FTK. The only limitation is the amount of gas in the cylinder and the flow of the regulator. The 34 liter cylinder for example with a 0.2LPM regulator has approximately 170 minutes of continuous calibration run time. Replacement cylinders are available. The gas cylinder should be replaced when the pressure gauge on the regulator shows 25-psi or less.

Note: Gas testing results can vary depending upon temperature, humidity, test duration and other variables. For optimum results it is suggested that the unit be in continuous operation for a minimum of 72 hours, in a stable environment and at standard conditions before proceeding with testing.

Gas Testing Preparing the Humidifier

1. Open the two plastic halves of the humidifier by holding one half steady and turning the other one counterclockwise. Then pull them apart.

2. Pull out the orange sponge and wet it.

3. Squeeze the sponge such that there are not any visible drops of water on the sponge (it should only be damp).

4. Put the sponge back into the humidifier housing and close it.

Assembling the Regulator, Hose and Test Hood

1. Open the FTK. Connect the 300 ppm gas cylinder to the regulator.

2. Connect a 6 inch piece of tubing from the non-sponge end of the humidifier to the test hood.

3. Connect the sponge end of the humidifier to the tubing from the regulator

Testing the Fan Relay

1. Remove the Philips screw on the front of the RD-6. Remove the front cover.

2. Check the pressure gauge on the regulator. If you have 25-psi or less you will need to replace the gas canister.

3. Place the Test Hood over the gas sensor.

Note: The time to activate the Fan relay depends on the delay setting.

4. Turn on the regulator to start the gas flow and wait with the gas applied continuously.

5. With the display function turned “On”, the RD-6 will show the current concentration of gas or “0” (zero) in clean air. When the gas concentration reaches the Fan Relay setting (100 ppm, for example) the display will flash back and forth between “FAn” and “100”. With the display function turned ”OFF”, the display does not show the gas concentration, but will show “FAn” as long as the fan relay is activated.

Note: If the Fan relay does not change state within 2 minutes, there are four possibilities: a. Gas cylinder is empty, check the pressure gauge. Replace the gas cylinder if 25psi or less. b. Detector has fan relay set to disable (diS) or higher than 300 ppm. Set fan relay to 100 ppm and repeat the test. c. Detector has fan relay delay set to 3 or more minutes. Set fan relay to 0 minutes and repeat the test. d. Detector is in need of servicing (return unit to factory for servicing).

6. Remove the gas from the sensor. Proceed to Test the Alarm relay or replace the top cover. Fan relay test is complete.

Testing the Alarm Relay Note: The gas concentration to activate the Alarm relay depends on the setting.

1. Connect the 300 ppm cylinder of Refrigerant to the regulator.

2. Check the pressure gauge. If there is 25psi or less the cylinder should be replaced.

3. Place the test hood over the gas sensor. Turn on the regulator to start the gas flow.

4. The Fan relay should activate according to the settings.

5. With the display function turned “On” and the gas concentration reaching the Alarm Relay setting, (150 ppm, for example) the

display will flash back and forth between “ALr” and “150”. The buzzer will sound indicating “Alarm” if the buzzer is turned “On”. With the display function turned off the display does not show the gas concentration, but will show “ALr” when the Alarm relay is activated.

Note: If the Alarm relay fails to operate within 2 minutes, there are three possibilities:

a. Gas cylinder is empty, check the pressure gauge. Replace the gas cylinder if 25-psi or less. b. Detector has Alarm relay set to disable (diS) or higher than 300 ppm. Set Alarm relay to 150 ppm and repeat the test. c. Detector is in need of servicing (return unit to factory for servicing).

6. Remove the gas from the sensor after Test. Proceed to Test the 4-20mA output or replace the top cover. Alarm relay test is

complete.

Testing the 4-20mA current loop

1. Connect the 300 ppm cylinder of Refrigerant to the regulator.

2. Check the pressure gauge. If there is 25-psi or less the cylinder should be replaced.

3. Place the test hood from the regulator over the gas sensor. Turn on the regulator to start the gas flow.

4. The Fan relay should activate according to the settings.

5. The Alarm relay should activate according to the settings.

6. The 4-20 mA output should ramp up from 4mA in clean air to 9 mA at 300 ppm. See 4-20 mA diagram on page 7.

Note: If the 4-20mA output does not ramp up within 2 minutes, there are three possibilities:

a. Gas cylinder is empty, check the pressure gauge. Replace the gas cylinder if 25-psi or less. b. Detector has 4-20 mA option set to “OFF”. Set 4-20mA option to “On” and repeat the test. c. Detector is in need of servicing (return unit to factory for servicing).

7. Remove the gas from the sensor. Re-assemble the RD-6 (make sure the LED is aligned with the front case hole). 4-20 current

loop test is complete.

Quick Gas Test

A butane cigarette lighter can be used to perform a functionality test of the RD-6. This test allows installers to do a quick functionality test of the gas sensor.

1. Units to be tested must be powered continuously for a minimum of 3 minutes before proceeding.

2. For optimum test results, the unit should be in clean air and be in a low ambient air flow.

3. Check that the RD-6 status indicator light is illuminated, green continuously. If not, do not proceed with tests. See RD-6 Trouble

Indicator section in these User Instructions.

4. The display option should be set to “On” and reading 0 ppm in clean air.

5. With the RD-6 cover on, aim the lighter into the sensor grate area (under “DO NOT PAINT”) on the front cover and release the

gas (without igniting the flame) for 1 second or less

6. Wait for a few seconds. The digital display should climb indicating the increased gas concentration at the sensor confirming a

pass of the quick test. Note: If the Display does not change within 10 seconds, consider these possibilities: a. Lighter is empty. b. Detector is in need of servicing (return unit to factory for servicing).

7. Wait for the display to return to 0 ppm and configure options to desired settings.

+ 50 hidden pages

Macurco RD-6 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual