RKI Instruments 61-0192RK User Manual

61-1006RK/61-0192RK

Combustible Gas Detector

Operator’s Manual

Part Number: 71-0228RK
Revision: P1
Released: 9/26/11

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.

61-1006RK/61-0192RK Combustible Gas Detector

Product Warranty

RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free fro m 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 assume indemnification fo r any accident or dama g e ca u s e d by the operation of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.

61-1006RK/61-0192RK 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Replacing the IR LEL Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

61-1006RK/61-0192RK Combustible Gas Detector

Overview

This manual describes the 61-1006RK 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 61-1006RK combustibl e gas detecto r includes a ju nction box. This manual may also be
used for the 61-0192RK combustible gas detector which does not include a junction box
and is normally mounted in one of a controller’s conduit hubs. If you are using a
61-0192RK combustible gas detector, disr eg ard all references to the junction box and
junction box terminal block.

Specifications

Table 1 lists specifications for the combustible gas detector.

Table 1: 61-1006RK Specifications

Target/Calibration Gas With Junction Box

61-1006RK-CH4: Methane

Without Junction Box

61-0192RK-CH4: Methane

Area Classification Explosionproof for Class I, Groups B, C, and D
Sampling Method Diffusion
Detection Range 0 to 100% volume
Response Time 90% in 45 seconds
Accuracy ± 5% of reading or ± 2% of full scale (whichever is greater)

WARNING: When using the 61-1006RK/61-0192RK, you must follow the instructions

and warnings in this manual to assure proper and safe operation of the
61-1006RK/61-0192RK and to minimize the risk of personal injury. Be sure
to maintain and periodically calibrate the 61-1006RK/61-0192RK as
described in this manual.

61-1006RK/61-0192RK C o m bu st i bl e G a s D et e c to r • 1

Description

The 61-1006RK combustible gas detector is calibrated to methane. The detector is an
infrared type of detector which has some advantages over a catalytic type of combustible
detector. The infrared d e tector 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 61 -1006RK. 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 j unction
box.

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 ensure that there is enough room to install a
calibration cup on the detector during calibration.

2 • 61-1006RK/61-0192RK 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 .38

3.65

7.10 max

Rubber
Spacers
3X

J-Box

CH4 IR Detector

.75

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).

61-1006RK/61-0192RK C o m bu st i bl e G a s D et e c to r • 3

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 contro ller.

2. Turn off or unplu g power to the controller.

3. If the detector is mounted remotely from a controller using the junction box, proceed
to step 4.

If the detector is mounted directly to a controller, it is normally factory wired. Confirm
that the detector’s wires are connected to the appropriat e contr oller det ector termin als
and skip to “S tart Up” on page 6. See F igu re 2, the c ontroller operat or’s manual, and
the controller’s detector head specification sheet for the 61-0192RK-CH4 detector for
the wiring connections.

4. Remove the cover from the junction box.

5. Guide a four-conductor, shielded cable or four wires in conduit through the unused
conduit hub of the junction box. Use appropriate conduit fittings and construction
technique for the environmental rating and hazardous location classification of the
junction box. The junction box is rated NEMA 4X and classified explosion proof for
Class I, Groups B, C, and D.

6. Connect the detector leads to the terminal blo ck in the junction box.

CAUTION: Leave the shield drain wire insulated and disconnected at the 61-1006RK. You will

connect the opposite end of the cabl e’s drain wire at the controller.

7. Secure the junction box cover to the junction box.

8. Route the cable or wires in conduit leading from the detector through one of the
conduit hubs at the controller housing. Use appropriate conduit fittings and
construction technique for the environmental rating of the controller. RKI controllers
are typically rated NEMA 4X.

CAUTION: Do not route power and detector wiring through the same conduit hub. The power

cable may disru pt the transmission of the detect or signal to the controller.

9. Connect the wires to the applicable controller terminal strip. See the controller
operator’ s manual and the controller’s detector head specification sheet for the
61-1006RK-CH4 detector.

10. If using shielded cable, connect the cable’s drain wire to an available chassis ground at
the controller. R KI controllers typically have a ground stud that is a convenient
grounding location.

4 • 61-1006RK/61-0192RK Combust ible Gas Detector

Cable Shield

Red

Whit e

Red
White
Green
Black

Controller Housing

Green

Black

CH4 IR Detector

Controller LEL
Detector
Terminals

Figure 2: Wiring the Combustible Gas Detector to a Controller

61-1006RK/61-0192RK C o m bu st i bl e G a s D et e c to r • 5

Start Up

This section describes procedures to start up the combustible gas detector and place the
detector into normal operation.

Introducing Incoming Power

1. Complete the installation procedures described earlier in this manual.

2. Ve rify 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 control ler, 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 minute s before you continue with the next

section, “Setting the Zero Reading”.

Setting the Zero Reading

WARNING: Do not remove the junction box cover while the circuits are energized

unless the area is determined to be non-hazardous. Keep the junction box
cover tightly closed during operation.

CAUTION: I f you suspect the presen ce of combustible gas in the monitori ng environment, use a

zero air calibration cylinder to introduce “fresh air” to the detector and verify an
accurate zero reading.

1. V erify 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.

6 • 61-1006RK/61-0192RK Combust ible Gas Detector

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.

Preparing for the response test

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 operator’s manual for directions to set the zero reading.

3. Screw the calibration cup onto the detector.

4. Use the sample tubing to connect the regulator to the calibration cup.

5. Screw the regulator into the calibration cylinder.

Performing the response test

1. Turn the on/off knob on the regulator counterclockwise to open the regulator.

2. Apply gas to the detector for one mi nute.

3. Verify that the reading is within ± 20% of the ga s concentration.

61-1006RK/61-0192RK C o m bu st i bl e G a s D et e c to r • 7

NOTE: If the reading is not within ± 20% of the gas concentration, calibrate the detector

as describe d in “Calibrat i on” on page 9.

4. Turn the on/off knob clockwise to close the regulator.

5. Unscrew the regulator from the calibration cylinder.

6. Unscrew the calibration cup from the detector.

7. When the display reading falls below the alarm setpoints, return the controller to
normal operation or enable external alarms.

8. Store the component s of the calibr ation kit in a safe place.

Biannually

Calibrate the detector every six months as described in “Calibration” on page9.

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.

• 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.

8 • 61-1006RK/61-0192RK Combust ible Gas Detector

Replacing the IR LEL Detector

1. Turn off the contro ller.

2. Turn off power to the controller.

3. Remove the 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.

5. Unscrew the detector from the junction box.

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. Connect the 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 junction box.

9. Turn on power to the controller.

10. Turn on the controller.

11. Calibrate the replacement detector as described in “Calibration” on page 9.

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.

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.

Calibration

This section describes how to calibrate the combustible gas detector. It includes
procedures to prepare for calibration, set the zero reading, set the response reading and
return to normal operation.

W ARNING: The controller 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.

61-1006RK/61-0192RK C o m bu st i bl e G a s D et e c to r • 9

Prepari ng for Ca libration

1. Screw the calibration cup onto the detector.

2. Screw the regulator into the calibration cylinder.

3. Place the controller into its calibration program.

Setting the Zero Reading

CAUTION: I f yo u suspect the monitor i ng environment is not free of combus tible 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 tha t the detector is in a fresh air environment.

2. Follow the direction s in the controller’s operator’s manual for setting the zero
reading.

Setting the Response Reading

1. Use the sample tubing to connect the regulator to the calibration cup.

2. Follow the direction s in the controller’s operator’s manual for setting the response
reading (span).

3. 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.

4. Allow the gas to flow to the detector for 1 minute before continuing with the
directions.

5. 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.

Returning to Normal Operation

1. Allow the reading at the con troller 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 to decrease below the alarm points, then

unwanted alarms may occur.

2. Ve rify that the controller display reading decreases and stabilizes at 0%LEL.

3. Store the components of the calibration kit in a safe and convenient p lace.

10 • 61-1006RK/61-0192RK Combus tible Gas Detector

Parts List

Table 3 lists replacement parts and accessories for the 61-1006RK combustible gas detector.

Table 3: Parts List

Part Number Description

18-0400RK-01 Junction box with spacers
61-0192RK-CH4 Methane infrared LEL detector
71-0228RK 61-1006RK/61-0192RK Combustible Gas Detector Operator’s Manual

(this document)
81-0013RK-01 Calibration cylinder (50% volume Methane i n 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

61-1006RK/61-0192RK C o m bu st i bl e Ga s D e te c to r • 1 1