RKI Instruments 61-1001RK-05 User Manual

61-1001RK-05

Hydrogen Detector

Operator’s Manual

Part Number: 71-0195RK
Revision: A
Released: 4/12/11

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
3 and 6 months, but can be required more often or less often
based on your usage.

61-1001RK-05 Combustible Ga s Detector

Product Warranty

RKI Instruments, Inc., warranties 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:

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.

61-1001RK-05 C o mb u st ib l e G a s D e te c to r

Table of Contents

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

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

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

NC-6205-05 Hydrogen Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Mounting the Hydrogen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Wiring the Hydrogen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Replacing the Hydrogen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

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

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

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

61-1001RK-05 Combustible Ga s Detector

Overview

!

This manual describe s th e 61-1001RK-05 hydrogen detector (i nt ern al ampli fier type). This
manual also describes how to install, start up, maintain, and calibrate the detector 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 hydrogen detector.

The 61-1001RK-05 hydrogen detector includes the NC-6205-05 hydrogen detector and a
junction box. This manual may also be used for the NC-6205-05 hydrogen 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 NC-6205-05 hydrogen detector, disregard all references to the
junction box and junc tion box terminal strip.

Specifications

WARNING: Do not use this product in a manner not specified in thi s instruction

Table 1 lists specifications for the hydrogen detector.

manual.

Table 1: 61-1001RK-05 Specifications

Description Specifications

Target Gas Hydroge n
Area Classification Explosion proof 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% LEL (whichever is greater)

NOTE: The following symbol on the detector label is a caution to the user to refer to this

documentation for installati on instructions:

WARNING: When using the 61-1001RK-05, you must follow the instructions and

warnings in this manual to assure proper and safe opera tion of the
61-1001RK-05 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 61-1001RK-05 as described in this
manual.

61-1001RK-05 C om b us t ib l e G as D et ec t or • 1

Description

r
r,

This section describes th e components of the NC- 6205-05 and 61-1001RK -05 detectors . The
61-1001RK-05 inclu des the NC-6205-05 hydrogen detector and a junction box. A four
point terminal strip is provided inside the junction box for detector connections. The
NC-6205-05 does not include a junction box.

Rubbe
Space
3X

Red

White

Green

Black

J-Box

Hydrogen Detector

Figure 1: 61-1001RK-05 Component Location

NC-6205-05 Hydrogen Detector

The hydrogen 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 NP T nipple with a sinter ed
metal flame arrestor on one end allowing ambient air to diffuse into the detector. The
flame arrestor also con tains any spark s which may occur within the detect or. The detector
has a built in molecular sieve that only allows hydrogen to diffuse into 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 flame arrestor guard screws onto the bottom of
the detector (flame arrestor end). The flame arrestor guard protects the flame arrestor
from damage and is permanentrly bonded to the detector housing. Four color-coded leads
extend from the top of the detector. The leads allo w you to connect the detector to the
amplifier.

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 conduit hubs allow you to
mount the detector to the junction box and connect the wiring from the detector to a
controller. Three spacers insta lled on the back of the junction box control the distance of
the junction box from a mounting surface and ensure that there is enough room to install a
calibration cup on the detector during calibration.

The bottom conduit hub includes a 3/4 in. x 1/2 in. reducer that allows you to screw the

2 • 61-1001RK-05 Combustibl e Gas Detector

Installation

detector into the hub. The terminal block within the junction b ox facilita tes the wiring
process. A cover on the front of the junction box allows ac c ess to the interior of the
junction box.

This section describes procedures to mount the hydrogen detector in the monitoring
environment and wire the detector to a contro ller.

NOTE: The NC-6205-05 detector retains its explosion proof classification only when

installed in the explosion proof junction box. The detecto r is not explosion proof
if installed in a controller conduit hub.

Mounting the Hydrogen 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.

8.0 REF

2.57 MAX

• Select a site where the target gas is likely to be found first. For hydrogen, which is

lighter than air, mount the detector near the ceiling or where hydrogen is most
likely to accumulate.

1/2'' NPT

3/4 NPT

Female

3.65

7.50 max

J-Box

3/4 x 1/2

Reducing

Bushing

H2 LEL

Detector

2.70 .38

Rubber
Spacers
3X

Ø 1.50

NC-6205RK-05

.75

61-1001RK-05

Figure 2: Mounting the Hydrogen Detector

61-1001RK-05 C om b us t ib l e G as D et ec t or • 3

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

facing down (see Figure 2).

Wiring the Hydrogen Detector to a Controller

WARNING: Always verify that the power to the controller is off before you make

wiring connections.

1. Turn off the controlle r.

2. Turn off 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 5. See F igu re 3, the c ontroller operat or’s manual, and
the controller’s detector head specification sheet for the NC-6205-05 detector for the
wiring connection s.

4. Remove the junction box cover.

WARNING: To maintain the explosion proof classification of the detector/junction box

combination, a conduit seal must be used within 18 inches of the junction
box conduit hub used for wiring to the controller.

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 block in the junction box.

CAUTION: If using shielded cable, leave the drain wire insulated and disconne cted at the

detector. You will connect the op posite end of the cable’s drain wire at the controller.

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

8. Route the cable or wires leading from the hydro gen 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
61-1001RK-05 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 • 61-1001RK-05 Combustibl e Gas Detector

J-box

Terminal Strip

Black

C ontroller LEL

Detector Terminals

RED
WHITE
GREEN
BLACK

Green
White

Red

Hydrog en Dete ctor

Figure 3: Wiring the Hydrogen Detector to a Controller

Detector Wires

Start Up

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

Introducing Incoming Power

1. Complete 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.

61-1001RK-05 C om b us t ib l e G as D et ec t or • 5

3. Turn on power to the controller.

4. Turn on the controller.

5. Verify that the controller is on and op erating 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

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: If you suspect the presence of hydrogen in the monitoring environment, use the 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

2. Verify a reading of 0% LEL at the controller.

3. Perform a zeroing operation at the controller. See the contr oller operato r’s manual for

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 hydrogen detector. It includes daily, monthly, and quarterly
procedures.

Daily

Verify a display reading of 0% LEL at the controller. Investigate significant changes in the
reading.

Monthly

hydrogen and of no rmal oxygen conc entration, 20.9%).

If the display reading is 0% LEL, start up is complete. The hydrogen detector is in
normal operation. If the display reading is not 0% LEL, continue with step 3.

directions.

This procedure describes a test to verify that the hydrogen detector responds properly to
the target gas.

WARNING: The controller is not an active gas monitoring device during the response

test procedure.

6 • 61-1001RK-05 Combustibl e Gas Detector

NOTE: Performing a response test on the hydrogen detector may cause alarms. Be sure

to put the controller into its calibration program or disable external alarms befor e
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 length of sample tubing.

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.

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.

3. Screw the regulator into the calibration cylinder.

4. Screw the calibration cup onto the bottom of the detector.

5. Use the calibration kit sample tubing to connect the regulator to the calibration cup.

Performing the response test

1. Turn the regulator’s on/off knob counterclockwise to open the regulator. Gas will
begin to flow.

2. Allow the gas to flow for one minute.

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

NOTE: If the readings are not within ± 20% of the gas concentration, calibrate the

detector as described in the Calibration section of this manual.

4. Turn the regulator knob clockwise to close the regulator.

5. Unscrew the regulator from the calibration cylind er.

6. Unscrew the calibration cup from the detector.

7. When the display reading falls below the ala r m setpoints, return the controller to
normal operation.

8. Store the components of the calibration kit in a safe place.

Quarterly

Calibrate the detector as described in the Calibration section of this manual.

61-1001RK-05 C om b us t ib l e G as D et ec t or • 7

Troubleshooting

The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the hydrogen 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 Hydrogen 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
three mont hs.

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 calibration gas is
not an appr opriate
concentration.

• 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. Verify that the calibration gas
concentration is appropriate for the
detector.

3. If the calibration/response difficulties
continue, replace the detector.

4. If the calibration/response difficulties
continue, contact RKI for further
instruction.

Replacing the Hydrogen Detector

1. Turn off the controlle r.

2. Turn off power to the controller.

3. If the detector is installed directly on a controller, open the controller door.
If the detector is installed remotely from a controller in a junction box, remove the

junction box cove r.

4. If the detector is installed directly on a controller, disconnect the detector leads from
the detector terminal strip in the controller. Note the position of the color-coded leads
as you remove them.

If the detector is installed remotely from a controller in a junction box, disconnect the
detector leads from the terminal block in the junction box. Note the position of the
color-coded leads as you remove them.

5. Unscrew the detector from the controller conduit hub or junction box conduit hub.

6. Guide the detector leads of the replacement detector through the controller conduit

8 • 61-1001RK-05 Combustibl e Gas Detector

hub or junction box conduit hub, then screw the mounting threads of the detector into
the hub. If necessary for environmental conditions, apply thread sealant or teflon tape
to the hub and/or detector threads to seal them.

7. If the detector is installed directly on a controller, connect the detector leads to the
appropriate detector terminal strip terminals. See Figure 3 for wiring to a generic
controller. See the controller operator’s manual and the controller ’s detector head
specification sheet for the NC-6205-05 detector fo r wirin g specif ic to your controller.

If the detector is installed remotely from a controller in a junction box, connect the
detector leads to the terminal block the same way the old detector was wired (see
Figure 3). See the controller operator’ s manual and the controller’s detector head
specification sheet for the 61-1001RK-05 detector to verify the connections to the
controller are correct.

8. If the detector is installed remotely from a controller in a junction box, reinstall the
junction box cove r.

9. Turn on or plug in power to the controller.

10. Turn on the controller and place into normal operation.

CAUTION: Allow the replacement detector to warm up for 5 minutes before you continue with

the next step.

11. Calibrate the replacement detector as described in the Calibration section of this
manual.

Calibration Frequency

Although there is no particular calibration frequency that is correct for all applications, a
calibration frequency of every 3 to 6 months is adequate for most hydrogen detector
applications. Unless experience in a particular application dictates otherwise, RKI
Instruments, Inc. recommends a calibration frequency of every 3 months.

If an application is not very demanding, for example detection in a clean, temperature
controlled environment where hydrog en is not normally present and calibration
adjustments are minimal at calibration, then a calibration frequency of every 6 months is
adequate.

If an application is very demanding, for example if hydrogen is present often and in
significant concentrations or the environment is not well controlled, then more frequent
calibration than e v ery 3 mo nt h s m ay be n e ces s ary. If potential catalyst poisons are known
or likely to be present, more frequent ca libration than every 3 months will be necessary.

Calibration

This section describes how to calibrate the hydrogen 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.

61-1001RK-05 C om b us t ib l e G as D et ec t or • 9

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.

Prepari ng for Ca libration

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.

1. Screw the calibration cup onto the bottom of the detector.

2. Screw the regulator into the calibration cylinder.

3. Use the calibration kit sample tubing to connect the regulator to the calibration cup.

4. Place the controller into its calibration program or disable external alarms.

NOTE: Calibrating the hydrogen detector may cause alarms. Be sure to put the controller

into its calibration program or disable external alarms before continuing.

Setting the Zero Reading

NOTE: If you can ver i fy t ha t th e hy drogen detector is in a fresh air environment, you do

not need to apply zero air to the detector before adjusting the zero reading.

1. Follow the directions in the controller operator’s manual for setting the zero reading.

2. When the instructions call for applying z e ro air to the detector, turn the regulator’s
on/off knob counterclockwise to open it.

3. Allow the gas to flow for one minute.

4. Set the zero reading according to the controller operator’s manual.

5. Turn the regulator’s on/off knob clockwise to close it.

6. Leave the sample tubing connected to the regulator and the calibration cup.

Setting the Response Reading

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

2. When the directions call for exposing the detector to gas, turn the regulator’s on/off
knob counterclockwise to open it.

3. Allow the gas to flow for one minute before continuing with the directions.

4. After setting the response reading, turn the regulator’s on/off knob clockwise to close
it.

5. Unscrew the regulator from the cylinder.

Returning to Normal Operation

1. Unscrew the calibration cup from the detector.

10 • 61-1001RK-05 Combustib le Gas Detector

Parts List

Part Number Description

NOTE: For convenience, leave regulator and calibration cup connected by the sample

tubing.

2. When the controller display reading falls below the alarm points and then return the
controller to normal operation.

NOTE: If you do not allow the gas reading to decrease below the alarm points, then

unwanted alarms may occur.

3. Verify that the controller display reading decreases and stabilizes at 0 %LEL.

4. Store the components of the calibration kit in a safe and convenient place.

Table 3 lists replacement parts and accessories for the 61-1001RK-05 hydrogen detector.

Table 3: Parts List

18-0400RK-01 Junction box with spacers
NC-6205-05 Replacement hydrogen detector
71-0195RK 61-1001RK-05 Hydrogen Detector Operator’s Manual (this document)
81-0002RK-01 Calibration cylinder, 50 %LEL hydrogen in air, 34 liter steel
81-0076RK-01 Zero air calibration cylinder, 34 liter steel
81-1050RK Regulator, 0.5 LPM with pressure gauge and flow control kn ob, for 17

and 34 liter steel calibration cylinders

81-1117RK Calibration cu p

61-1001RK-05 Combustible Gas Detector• 11