RKI Instruments 61-1001RKSS Operator's Manual

61-1001RKSS

Hydrogen Detector

Operator’s Manual

Part Number: 71-0229RK
Revision: P1
Released: 1/11/18

www.rkiinstruments.com

WARNING

Read and understand this instruction manual before operating
detector. Improper use of the detector 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.
Typical calibration frequencies for most applications are between
3 and 6 months, but can be required more often or less often
based on your usage.

61-1001RKSS Hydrogen 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:

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or
repair procedures not in accordance with the operator’s manual. This warranty indicates
the full extent of our liability, and we are not responsible for removal or replacement costs,
local repair costs, transportation costs, or contingent expenses incurred witho u t 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. IN CLUDING BUT NOT LIMITED TO, THE
WARRANTY OF MERCHANTABILITY OR F ITNESS 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 d istributors,
dealers, and representatives as appointed by RKI Instruments, Inc.

We do not assume indemnification for any a ccident or damage caused by the opera tion of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.

61-1001RKSS Hydrogen Detector

Table of Contents

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

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

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

NC-6205-01 Hydrogen Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

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

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

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

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

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

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

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

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

Replacing the Hydrogen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

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

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

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

61-1001RKSS Hydrogen Detector

Overview

This manual describes the 61-1001 RKSS hydrogen detector (internal amplifier 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.

Specifications

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

Table 1 lists specifications for the hydrogen detector.

Description Specifications

Target Gas Hydrogen

manual.

Table 1: 61-1001RKSS Specifications

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)

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

warnings in this manual to assur e proper and safe operation of the
61-1001RKSS and to minimize the risk of pe rsonal injury. Be sure to
maintain and periodically calibrate the 61-1001RKSS as described in this
manual.

61-1001RKSS Hydrogen Detector • 1

Description

J-Box

Red

Green

Black

Locking Set Screw

White

This section describes th e co mpo nen ts of t he NC -620 5-0 1 and 61-1001RKSS detectors. The
61-1001RKSS includes the NC-620 5-01 hydr ogen detector a nd a jun ction box. A four po int
terminal strip is provided inside the junction box for detector connections.

Figure 1: 61-1001RKSS Com ponent Location

NC-6205-01 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 NPT nipple with a
sintered metal flame arrestor on one end allowing ambient air to diffuse into the detector.
The flame arrestor also contains any sparks which may occur within the detector. The
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 dete ctor allow you to
mount it into the bottom conduit hub of the junction box. The controller conduit hubs are
normally 3/4 in. NPT, so a 3/4 in. x 1/2 in. NPT re ducer may be ne cessary to install the
hydrogen detector. A rainshield screws onto the bottom of the detector (flame arrestor
end). The rainshield helps protect the detector from rain and debris in the monitoring
environment. Four color-coded leads extend from the top of the detector. The leads allow
you to connect the detector to the terminal block.

Junction Box

The stainless steel, corrosion resistant 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 th e detector to the junction box and
connect the wiring from the detector to a controller. An O-ring seals the interface between
the junction box cover and the junction box base.

The bottom conduit hub includes a 3/4 in. x 1/2 in. NPT reducer that allows you to screw
the detector into the hub. The terminal block within the junction box facilitates the wiring
process. A cover on th e front of the junction box allows access to the interior of the

2 • 61-1001RKSS Hydrogen Detector

Installation

3/4 NPT
Female,
2X

.20 Dia. x .45
Slot, 2X

3.66

3.15

2.40

Hydrogen Detector

J-Box

.75

3.34

7.40 MAX

junction box. A locking set screw on the junction box co ver allows you to secure the
junction box cover and prevent it from being removed.

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

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. Make sure

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 hydrogen, which is

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

Figure 2: Mounting the Hydrogen Detector

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

facing down (see Figure 2).

61-1001RKSS Hydrogen Detector • 3

Wiring the Hydrogen Detector to a Controller

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

wiring connections.

1. Turn off the controller.

2. Turn off power to the controller.

3. Remove the junction box cover.

4. 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 f or
Class I, Groups B, C, and D.

5. Connect the detector leads to the terminal block in the junction box.

CAUTION: If using shielded cable, leave the drain wire insulated and disconnected at th e

detector. You will conn ect the opposite end of the cable’s drain wire at the c ontroller.

6. Secure the junction box cover to the junction box.

7. Route the cable or wires leading from the hydrogen 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 co nduit hub. The power

cable may disru pt the transmission of the detector signal to the controller.

8. Connect the wires to the applicable controller terminal strip. See the controller
operator’s manual and the controller’s detector head sp ecif ication sheet for the
61-1001RKSS detector.

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

4 • 61-1001RKSS Hydrogen Detector

Red
White
Green
Black

J-Box

Terminal Strip

Detector Wires

Green

Black

White

Hydrogen Detector

Controller LEL

Detector Terminals

Red

Figure 3: Wiring the Hydrogen Detector to a Controller

61-1001RKSS Hydrogen Detector • 5

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.

3. Turn on power to the controller.

4. Turn on the controller.

5. Verify that the controller is on and operating properly. Refer to the controller
operator’s manual.

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
hydrogen and of normal oxygen concentration, 20.9%).

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

3. Perform a zeroing operation at the controller. See the controller operator’s manual for
directions.

6 • 61-1001RKSS Hydrogen 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 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

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.

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 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 flo w 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.

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 cali bration 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.

61-1001RKSS Hydrogen Detector • 7

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

NOTE: If the readings are not within ± 20% of the ga s 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 cylinder.

6. Unscrew the calibration cup from the detector.

7. When the display reading fall s below the alarm 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.

Troubleshooting

The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the hy dro gen detector.

NOTE: This troubleshooting guide describes detector problems only. See the controller

operator’s manual for problems you may encounter 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 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 calibration gas is
not an appropriate
concentration.

• The detector is
malfunctioning.

1. Verify that the detector wiring is
correct and secure.

2. Calibrate the detector.

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.

8 • 61-1001RKSS Hydrogen Detector

Replacing the Hydrogen Detector

1. Turn off the controller.

2. Turn off power to the controller.

3. Remove the junction box cover.

4. 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
hub or junction box conduit hub, then screw the mounting threads of the detector into
the hub. If necessary for environmental conditions, apply thread sealan t or Teflon tape
to the hub and/or detector threads to seal them.

7. 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 61-1001RKSS detector to verify the connections to the
controller are correct.

8. Reinstall t he junction box cover.

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

10. Turn on th e 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 applica tions, 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 hydrogen is not normally present and calibration
adjustments are minimal at calibration, then a calibration freque ncy 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 every 3 months may be necessary. If potential catalyst poisons are known
or likely to be present, more frequent calibration than every 3 month s will be necessary.

61-1001RKSS Hydrogen Detector • 9

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.

WARNING: 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 flo w 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 Calibration

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 cali bration 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 verify that the hydrogen 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 cont roller operator’s manual for setting the zero reading.

2. When the instructions call for applyin g zero 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 clo ckwise 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 regula tor’s on/off
knob counterclockwise to open it.

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

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

10 • 61-1001RKSS Hydrogen Detector

Parts List

5. Unscrew the regulator from the cylinder.

Returning to Normal Operation

1. Unscrew the calibration cup from the detector.

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

tubing.

2. When the controller display reading falls below the alarm points, return the controller
to normal o peration.

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 d ecreases a nd 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 61-1001RKSS hydrogen detector.

Table 3: Parts List

Part Number Description

07-7151RK O-ring
10-5153RK Lid locking set screw
18-0416RK-11 Junction box with cover, stainless steel
71-0229RK 61-1001RKSS 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 cyli nder, 34 liter steel
81-1050RK Regulator, 0.5 LPM with pressure gauge and flow contro l knob, for 17 lit er

and 34 liter steel calibration cylinders (cylinders w ith external threads)
81-1117RK Calibration cup
NC-6205-01 Hydrogen detector

61-1001RKSS Hydrogen Detector • 11