61-1003RK/61-0190RK
Combustible Gas Detector
Operator’s Manual
Part Number: 71-0120RK
Revision: 0
Released: 2/11/11
www.rkiinstruments.com
WARNING
Read and understand this instruction manual before operating
detector . Improper use of the dete ctor 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.
T ypical calibration frequencies for most applications a re between
6 and 12 months, but can be required more often or less often
based on your usage.
61-1003RK/61-0190RK Combustible Gas Detector
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 fr o m date of shipment
from RKI Instruments, Inc. Any parts found defective withi n tha t 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 ser v ice, and
which must be cleaned, repaired, or replaced on a routine basis. Examples of such items
are:
W arranty 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 , a nd we are not r esponsible for removal or r eplacement costs,
local repair costs, transportation costs, or contingent expenses incurred without our prior
approval.
a) Absorbent cartridges d) Batteries
b) Pump diaphragms and valves e) Filter elements
c) Fuses
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 assu m e i ndemnification for any accident o r d amage caused by the op e ration of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.
61-1003RK/61-0190RK Combustible Gas Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IR LEL Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting the Combustible Gas Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiring the Combustible Gas Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacing the IR LEL Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembling the Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
61-1003RK/61-0190RK Combustible Gas Detector
Overview
This manual describes the 61-1003RK combustible gas detector. This manual also
describes how to install, start up, maintain, and calibrate the detector when 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 61-1003RK combustibl e gas detecto r includes a ju nction box. This manual may also be
used for the 61-0190RK 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 610190RK combustible gas detector, disr egard all references to the junction box and junction
box terminal block.
Specifications
Table 1 lists specifications for th e combustible gas detector.
Table 1: 61-1003RK Specifications
Target/Calibration Gas With Junction Box
61-1003RK-CH4: Methane
61-1003RK-HC: Propane
Without Junction Box
61-0190RK-CH4: Methane
61-0190RK-HC: Propane
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% of full scale (whichever is greater)
WARNING: When using the 61-1003RK/61-0190RK, you must follow the instructions
and warnings in this manual to assure proper and safe operation of the
61-1003RK/61-0190RK and to minimize the risk of personal injury. Be sure
to maintain and periodically calibrate the 61-1003RK/61-0190RK as
described in this manual.
61-1003RK/61-0190RK Co mb us t ib l e G as De t ec to r • 1
Description
The 61-1003RK combustible gas detector has two versions, the 61-1003RK-CH4 which is
calibrated to methane an d the 61- 1003RK-H C which is cal ibrated to pr o pane. The det ector
is an infrared type of detector which has some advantages over a catalytic type of
combustible detector . Th e 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 de tection of combustible gas in an
inert atmosphere.
This section describes the components of the 61-1003RK. They include the infrared LEL
detector and the junction box.
Infrared LEL Detector
The infrared LEL detector is made up of a miniature infrared combustible gas LEL
detector housed and encapsulated in a pipe nipple. The pipe nipple has 3/4 inch NPT
threads on each end and a 1-1/4 inch hex that allows removal or installation of the
detector with a wrench. A porous flame arrestor coated with a hydrophobic film that
repels liquids is on one end of the detector and allows sample gas to enter the d e tector.
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 terminal block in the junction
box.
To distinguish the propane detector from the methane detector (in case the replacement
detector label that is applied to one of the leads is lost), a short length of red shrink tubing
is applied to the white wire of the propane detector near where the wire comes out of the
nipple.
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 3/4” NPT conduit hubs
allow you to mount the detector to the junction box and connect the wiring from the
detector to a controller. The terminal block within the junction box facilitates the wiring to
the detector. A cover on the front of the junction box allows access to the interior of the
junction b ox. Th ree spac ers in stall ed on t he ba ck of the junction box control the distance of
the junction box from a mounting surface and insure that there is enough room to install a
calibration cup on the detector during calibration.
2 • 61-1003RK/61-0190RK Combust ible Gas Detector
Installation
This section describes procedures to mount the combustible gas detector in the
monitoring environment and wire it to a controller.
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. Ma ke sur e
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.
3/4 NPT
Female
2.70
0.38
3.65
7.1 Max
Junction
Box
Spacer, 3X
IR LEL
Detector
Figure 1: Mounting the Combustible Gas Detector
2. At the mounting site you select, hang or mount the junction box with the detector
facing down (see Figure 1).
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.
61-1003RK/61-0190RK Co mb us t ib l e G as De t ec to r • 3
2. Turn o ff or unplug power to the contro ller.
3. Remove the cover from the junction box. If the detector is already installed in the
junction box, go to step 6.
4. Guide the detector leads through the bottom conduit hub of the junction box, then
screw the mounting threads of the detector into the conduit hub.
5. Con nect th e detector leads to the terminal block in the junction box.
6. Guide a four-conductor, shielded cable or four wires in conduit through the top
conduit hub of the junction box. Connect the wires to the terminals opposite the
detector leads.
CAUTION: Leave the shield drain wire insulated and disconnected at the 61-1003RK. You will
connect the opposite end of the cabl e’s drain wire at the controller.
7. Secure the junction box cover to the jun ction box.
8. Route the cable or wires in conduit leading from the detector through one of the
conduit hubs at the controller.
CAUTION: Do not route power and detector wiring through the same conduit hub. The power
cable may disru pt the transmission of the detect or signal to the controller.
Cable Shield
Terminal Strip
Black
Green
White
Red
IR LEL
Detector
Red
White
Green
Black
Detector
Wires
Controller
LEL Detector
Terminals
Controller Housing
Figure 2: Wiring the Combustible Gas Detector to a Controller
4 • 61-1003RK/61-0190RK Combust ible 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. Com plete 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 or plug in power to the controller, then turn on the controller.
4. Verify that the controller is on and operating properly. Refer to the controller
operator’s ma nual.
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
CAUTION: If you suspect the presence of combustible gas in the monit oring environment, use a
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 and toxic gases and of normal oxygen content, 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 d e tector 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 co ntroller operator’s manual for
directions.
61-1003RK/61-0190RK Co mb us t ib l e G as De t ec to r • 5
Maintenance
This section describes maintenance procedures. It includes preventive maintenance,
troubleshooting, and component replacement procedures.
Preventive Maintenance
This section describes a preventive maintenance schedule to ensure the optimum
performance of the combustible gas detector. It includes daily, monthly, and biannual
procedures.
Daily
Verify a display reading of 0% LEL at the controller. Investigate significant changes in the
reading.
Monthly
This procedure describes a test to verify that the combustible gas detector responds
properly to the target gas.
WARNING: The controller is not an active gas monitoring device during the response
test procedure.
NOTE: Performing a response te st on the combustible detector may cause alarms. Be
sure to put the controller into its calibration program or disable external alarms
before performing this test
NOTE: The following procedure assumes the use of a calibration kit which includes a
calibration gas cylinder, a 0.5 LPM fixed flow regulator with an on/off knob, a
calibration cup for the detector, and a short piece of sample tubing to connect the
regulator to the calibration cup.
1. Place the controller into its calibration program or disable external alarms.
2. Verify that the controller display reading is 0% LEL.
If the controller reading is not 0% LEL, set the zero reading then continue this
procedure. See the controller instruction manual for directions to set the zero reading.
3. Screw the calibration cup onto the detector.
4. Use the sa mple tubing to connect the regulator to the calibration cup.
5. Screw the regulator into the calibra tion cylinder.
6. Turn the on/off knob on the regulator counterclockwise to open the regulator.
7. Apply ga s to the detector for one minute.
8. Verify that the reading is within ± 20% of the gas concentration.
NOTE: If the reading is not within ± 20% of the gas concentration, calibrate the detector
as describe d in “Calibrat i on” on page 8.
9. Turn the on/off knob clockwise to close the regulator.
6 • 61-1003RK/61-0190RK Combust ible Gas Detector
10. Unscrew the regulator from the calibration cylinder.
11. Unscrew the calibration cup from the detector.
12. When the display reading falls below the alarm setpoints, return the controller to
normal operation or enable external alarms.
13. Store the components of the calibration kit in a safe place.
Biannually
Calibrate the detector every six months as described in “Calibration” on page 8.
Troubleshooting
The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the combustible gas detector.
NOTE: This troubleshooting guide describes detector problems only. See the controller
operator’s manual for problems you may encounte r with the controller.
Table 2:Troubleshooting the Combustible Gas Detector
Condition Symptom(s) Probable Causes Recommended Action
Fail Condition • Controller indicates a
Slow or No
Response/
Difficult or
Unable to
Calibrate
fail condition.
• Detector responds
slowly or does not
respond to response
test.
• Unable to accurately
set the zero or
response reading
during calibration.
• Detector requires
frequent calibration.
Note: Under “normal”
circumstances, the
detector requires
calibration once every
six months.
Some applications may
require a more freque nt
calibration schedule.
Replacing the IR LEL Detector
• The detector wiring is
disconnected or
misconnected.
• The detector zero
signal is low enough to
cause a fail condition.
• The detector is
malfunctioning.
• The calibration cylinder
is low, out-dated, or
defective.
• The detector is
malfunctioning.
1. Verify that the detector wiring is
correct and secure.
2. Calibrate the det ect or.
3. If the fail condition continues, replace
the detector.
4. If the fail condition continues, contact
RKI for further instruction.
1. Verify that the calibration cylinder
contains an adequate supply of a
fresh test sample.
2. If the calibration/response difficulties
continue, replace the detector.
3. If the calibration/response difficulties
continue, contact RKI for further
instruction.
1. Turn off the controller.
2. Turn off power to the controller.
3. Remove th e junction box cover.
4. Disconnect the detector leads from the terminal block inside the junction box. Note
the position of the color-coded leads as you remove them.
61-1003RK/61-0190RK Co mb us t ib l e G as De t ec to r • 7
5. Unscrew the detector from the junction bo x.
6. Guide the detector leads of the replacement detector through the bottom conduit hub
of the junction box, then screw the mounting threads of the detector into the conduit
hub.
7. Con nect th e detector leads to the terminal block in the same position as the leads you
removed in step 4.
8. Secure the junction box cover to the jun ction box.
9. Turn on power to the controller.
10. Turn on the controller.
11. Calibrate the replacement detector as described in“Calibration” on page 8.
Calibration Frequency
Although there is no particular calibration frequency that is correct for all applications, a
calibration frequency of every 6 months is adequate for most infrared combustible
detector applications. Unless experience in a particular application dictates otherwise,
RKI Instruments, Inc. recommends a calibration frequency of every 6 months for the
infrared combustible detector.
Calibration
If an application is not very demanding, for example detection in a clean, temperature
controlled environment where the combustible target gas is not normally present, and
calibration adjustments are minimal at calibration, then a calibration frequency of every 9
to 12 months is adequate.
If an application is very demanding, for example if the environment is not well controlled,
then more frequent calibration than every 6 months may be necessary.
This section describes how to calibrate the combustible gas detector. It includes
procedures to assemble the calibration kit, set the zero reading, set the response reading
and return to normal operation.
W ARNING: The controll er is not an active gas monitoring device during the calibration
procedure.
NOTE: The following procedure assumes the use of a calibration kit which includes a
calibration gas cylinder, a 0.5 LPM fixed flow regulator with an on/off knob, a
calibration cup for the detector, and a short piece of sample tubing to connect the
regulator to the calibration cup.
Assembling the Calibration Kit
1. Screw the calibration cup onto the detector.
2. Use the sa mple tubing to connect the regulator to the calibration cup.
3. Place the controller into its calibration program or disable external alarms.
8 • 61-1003RK/61-0190RK Combust ible Gas Detector
NOTE: Calibrating the combustible detector may cause alarms. Be sure to put the
controller into its calibration program or disable external alarms before
continuing.
Setting the Zero Reading
CAUTION: If you suspect the mon itoring environment is not free of co mbustible vapors, use the
calibration kit and a zero air calibration cylinder to introduce “fresh air” to the
detector and verify an accurate zero setting
1. Verify that the detector is in a fresh air environment.
2. Follow the directions in the controller’s operator’s ma nual for setting the zero
reading.
Setting the Response Reading
1. Follow the directions in the controller’s operator’s manual for setting the response
reading (span).
2. When the directions call for exposing the detector to gas, screw the regulator into the
cylinder, turn the on/off knob counterclockwise to open the regulator, and allow the
gas to flow to the detector for 1 minute before continuing with the directions.
3. After setting the response reading, turn the on/off knob clockwise to close the
regulator, unscrew the regulator from the cylinder and remove the calibration cup
from the detector.
4. Allow the reading at the controller to decrease below the alarm points before
returning the controller to normal operation or enabling external alarms.
NOTE: If you do not allow the gas reading decrease below the alarm points, then
unwanted alarms may occur.
5. Verify that the controller display reading decreases and stabilizes at 0%LEL.
6. Store the components of the calibration kit in a safe and convenient place.
61-1003RK/61-0190RK Co mb us t ib l e G as De t ec to r • 9
Parts List
Table 3 lists replacement parts and accessories for the 61-1003RK combustible gas detector.
Table 3: Parts List
Part Number Description
18-0400RK-01 Junction box with spacers
61-0190RK-CH4 Methane infrared LEL detector
61-0190RK-HC HC infrared LEL detector (calibrated to propane)
71-0120RK 61-1003RK/61-0190RK Combustible Gas Detector Operator’s Manual
(this document)
81-0004RK-01 Calibration cylinder (50% LEL Propane in air, 34 liter)
81-0012RK-01 Calibration cylinder (50% LEL Methane in air, 34 liter)
81-0076RK-01 Zero air calibration cylinder (34 liter)
81-1050RK Regulator, 0.5 liter/minute, with gauge and knob, for 17- and 34-
liter calibration cylinders
81-1 10 3R K Calibration cup
10 • 61-1003RK/61-0190RK Combus tible Gas Detector
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