RKI Instruments 65-2340RKSS User Manual

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65-2340RKSS

Toxic Gas Transmitter

Operator’s Manual

Part Number: 71-0302RK

Revision: P1

Released: 1/21/14

RKI Instruments, Inc.

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.

65-2340RKSS Toxic Gas Transmitter

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 assume inde mn ification for any accident or dama g e c au s e d b y t he op e ration of this gas monitor, and our warranty is limited to the replacement of parts or our complete goods.

65-2340RKSS Toxic Ga s Trans mitte r

Table of Contents

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

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

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

Toxic Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mounting the Toxic Gas Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Wiring the Toxic Gas Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Replacing Components of the Toxic Gas Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

65-2340RKSS Toxic Gas Transmitter

Overview

This manual describes the 65-2340RKSS toxic gas transmitter. This manual also describes how to install, start up, maintain, and calibrate the toxic gas transmitter when used with a gas monitoring controller. A parts list at the end of this manual lists replacement parts and accessories for the toxic gas transmitter.

The 65-2340RKSS toxic gas transmitter can be used for various target gases which are listed in T able 1 below. For a particular target gas, the part number of the toxic transmitter will be of the format 65-2340RKSS-XXX. For example, 65-2340RKSS-NH3 is for ammonia (NH

Specifications

Table 1 lists specifications for the toxic gas transmitt er.

) detection.

Table 1: Specifications

Target Gas 65-2340RKSS-ASH3: Arsine (AsH

65-2340RKSS-CL2: Chlorine (Cl 65-2340R K SS-CL-10: C hlorine (Cl

)

65-2340RKSS-HCN: Hydrogen Cyanide (HCN) 65-2340RKSS-NH3: Ammonia (NH

65-2340RKSS-SO2: Sulphur Dioxide (SO 65-2340RKSS-PH3: Phosphine (PH

)

Sampling Method Diffusion Detection Range AsH

: 0 - 1.50 ppm

: 0 - 3.00 ppm

: 0 - 10.0 ppm

HCN: 0 - 15.0 ppm

: 0 - 75.0 ppm

: 0 - 6.00 ppm

: 0 - 1.00 ppm

Accuracy ± 10% of reading or ± 5% of full scale (whichever is greater) Signal Output 4 to 20 mA Response Time • Cl

and NH3: T90 in 90 seconds

• All others: T90 in 45 seconds

Operating Temperature & Humidity

WARNING: When using the 65-2340RKSS, you must follow the instructions and

• 14°F to 104°F (-10°C to 40°C)

• 20% to 90% Relative Humidity

warnings in this manual to assure proper and safe opera tion of the 65-2340RKSS and to minimize the risk of personal injury. Be sure to maintain and periodically calibrate the 65-2340RKSS as described in this manual.

65-2340RKSS Toxic Gas Tr a nsm itter • 1

Description

This section describes the components of the toxic gas transmitter. The toxic gas transmitter is a 4 - 20 mA type detector head. It consists of the toxic detector, amplifier, and juncti on box.

Factory Adjust Pot

Span Pot

Zero Pot

Red +TestPoint

Black - Test Point

J-B ox

Controller TerminalS trip

Amplifier

ZERO

SPAN

SIG /P W R

TOXIC OXY

Mounting Screw

Detector Termi nalStrip

Toxic Detector

Figure 1: Toxic Transmitter Component Location

2 • 65-2340RKSS Toxic Gas Transmitter

Toxic Detector

The toxic detector consists of the detector housing body, detector housing cap, splashguard, cap gasket, and the plug -in sensor.

Det e c tor H o us ing Body (different for each detector type)

Cap Gasket

Sensor (different for each detector type)

Detect or Ho usin g Cap

Splas h Guard (removable)

Figure 2: Toxic Detector Component Location

Detector Housing Body

The detector housing body protects the electronic components within the housing. Use the mounting threads at the top of the housing to screw the toxic detector into the 3/4” NPT hub on the bottom of the junction box. Two wires extend from the top of the detector housing body. Use these wires to connect the toxic detector to the amplifier. One of the wires is black and one of the wires is color coded depending on the detector type. See Figure 4 on page 7 for the color code assignments.

The housing body includes a 12 position connector at the bottom of the housing body. The plug-in sensor mates to this connector. A pre-amplifier located between the connector and the two interconnect wires conditions the sensor’s signal before the signal reaches the controller . Ea ch plug-in sensor type (Cl

for example) requires a diffe rent pr e-amplifier, so

there is a different detector housing body for each gas type.

Housing Cap, Cap Gasket, & Splashguard

The housing cap screws onto the detector housing. It retains the plug-in sensor and protects it from damage. A removable splashguard is screwed onto the detector cap to protect the sensor from impact damage, direct water spray, and splashing. Unscrew the detector cap to access the sensor for maintenance or replacement. A cap gasket seals the interface between the housing and cap.

Plug-In Sensor

The plug-in sensor is secured in the detector assembly by the housing cap. There is a different sensor for each target gas. Through a series of chemical and electrical reactions, the sensor produces an electrical output that corresponds to the detection range of the sensor.

Amplifier

The amplifier converts the electrical output from the detector to a 4 to 20 mA signal that corresponds to the detection range and transmits the signal to a gas monitoring controller .

65-2340RKSS Toxic Gas Tr a nsm itter • 3

A foam gasket that orients the amplifier and keeps it from rotating is installed on the bottom of the amplifier. The amplifier includes the detector terminal strip, controller terminal strip, zero pot, span pot, and test points (see Figure 1).

Controller Terminal Strip

The controller terminal strip is a two position plug-in style terminal s trip located at the top edge of the amplifier. Use the controller terminal strip to wire the transmitter to a controller.

Detector Terminal Strip

The detector terminal strip is a four position plug-in style terminal strip located below the controller terminal strip. Two of the positions are for use with an oxygen sensor and are not used in the toxic gas transmitter. Use the two detector terminal strip positions that are labelled “TOXIC” to connect the detector to the amplifier.

NOTE: The detector is factory-wired to the detector terminal strip. See “Wiring the Toxic

Gas Transmitter to a Controller” on page 6 for all wiring procedures related to the transmitter.

Zero Pot

The zero pot is located in the upper left corner of the amplifier (see Figure 1). Use a small flat blade screwdriver to turn the zero pot’s adjustment screw and adjust th e amplifier’s zero (fresh air) output during the start-up and calibration procedures. Turn the adjustment screw clockwise to increase the zero output and counterclockwise to decrease the zero output.

Span Pot

The span pot is located to the right of the zero pot (see Figure 1). Use a small flat blade screwdriver to turn the span pot’s adjustment screw and adjust the amplifier’s gas response output during the calibration procedure. Turn the adjustment screw clockwise to increase the span output and counterclockwise to decrease the span output.

CAUTION: The amplifier includes an additional potentiometer. It is factory-set. Do not adjust it.

Test Points

The test points are on the left side of the amplifier (see Figure 1). The test points produce a 100 mV to 500 mV output that corresponds to the transmitter’s 4 to 20 mA output. Use the test points and a voltmeter to measure the amplifier’s output during the start-up and calibration procedures. The black test point in the lower left corner is the negative (-) test point and the red test point below the zero pot is the positive (+) test point.

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 yo u to m oun t the 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.

A cover on the front of the junction box allows access to the interior of the junction box. A locking set screw on the junction box cover allows you to secure the junction box cover and prevent it from being removed.

4 • 65-2340RKSS Toxic Gas Transmitter

Installation

This section describes procedures to mount the toxic gas transm itter in the monitoring environment and wire the transmitter to a controller.

Mounting the Toxic Gas Transmitter

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 transmitter 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.

3.66

3.15

2.40

3/4 NPT

Conduit Hub

Text O riented

This W a y

.20 Dia. x .45 Slot, 2X

10.00 Max

Junction

Box

Toxic

Detector

Figure 3: Mounting the Toxic Gas Transmitter

65-2340RKSS Toxic Gas Tr a nsm itter • 5

1.10

2. At the monitoring site you select, hang or mount th e jun c tion box with the detector facing down (see Figure 3).

Wiring the Toxic Gas Transmitter to a Controller

WARNING: Always verify that 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. The detector leads are factory wired. Verify that the detector leads are wired to the amplifier’s detector terminal strip as shown in Figure 4.

5. To gain access to a plug-in terminal strip for wiring, pull it out o f its socket by grasping the terminal strip and pulling. The detecto r strip is keyed so that the controller and detector terminal strips cannot be reversed inadvertently.

6. Guide a two-conductor, shielded cable or two wires in conduit through the top conduit hub of the junction box.

7. Pull out the controller terminal strip, and connect the two wires to the terminal strip as follows (see Figure 4).

• Connect the positive wire to the SIG/PWR “+” terminal.

• Connect the signal wire to the SIG/PWR “S” terminal.

CAUTION: If shielded cable is used, leave the cable shield ’s drain wire disconnected and

insulated at the transmitter. You will connect the opposit e end of the cable’s drain wire to the controller’s chassis (earth) ground.

8. Reinstall the controller terminal strip into its socket.

9. Secure the junction box cover to the junction box.

10. Route the cable or wires leading from the toxic gas transmitter through one of the conduit hubs at the controller housing.

CAUTION: Do not route power and transmitter wiring through the same controller conduit hub.

The power cabl e may disrupt the transmission o f the transmitte r signal to the controller.

11. Connect the wires to the applicable detector/transmitter terminal strip at the controller as shown in Figure 4.

6 • 65-2340RKSS Toxic Gas Transmitter

Controller Detector/Transmitter

Terminals, Typical Designations

Controller Housing

Cable Shi eld

J-Box

Gas Type Table

ZERO

SPAN

SIG/PWR

Gas Type + Wire AsH3 brown

0-3ppmCl2

T OX IC OX Y

0- 10 ppmCl2

CL2 yellow CL-10 yel low HCN white NH3 red PH3 g reen

Black

SO2 blue

(+) S ee Ta ble

Toxi c Detector

Figure 4: Wiring the Toxic Gas Transmitter to a Controller

12. If shielded cable is used, connect the cable’s drain wire to an available chassis (earth) ground at the controller. RKI controllers typically have a ground stud that can be used to ground the cable’s drain wire.

65-2340RKSS Toxic Gas Tr a nsm itter • 7

Start Up

This section describes procedures to start up the toxic gas transmitter and place the transmitter 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 power to the controller.

4. Turn on the controller.

5. Verify that the controller is on and operating properly. R efer to the controller operator’s ma nual.

CAUTION: Allow the transmitter to warm up for 5 minutes before you continue with the next

section, “Setting the Zero Signal”.

Setting the Zero Signal

CAUTION: If you suspect the presence of toxic g a s in the monitoring environment, use the

calibration kit and the zero air calibration cylinder to introduce “fresh air” to t he detector and verify an accurate zero setti n g. Se e “Cal i b ration ” on pa ge 14 for instructions to apply zero air when setting the zero signal.

1. Verify that the transmitter is in a fresh air environment (environment known to be free of toxic gas).

2. Unscrew and remove the junction box cover from the junction box.

3. Set a voltmeter to measure in the millivolt (mV) range.

4. Plug the voltmeter leads into the test points on the amplifier. Plug the positive lead into the red + test point; plug the negative lead into the black - test point.

5. Verify a voltmeter reading of 100 mV (±2 mV).

6. If necessary, use a small flat-blade screwdriver to adjust the zero pot until the voltmeter reading is 100 mV (±2 mV).

7. Remove the voltmeter leads from the test points.

8. Secure the junction box cover to the junction box.

8 • 65-2340RKSS Toxic Gas Transmitter

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 toxic gas transmitter. It includes daily, monthly, and quarterly procedures.

Daily

Verify a display reading of 0 ppm at the controller. Investiga te significant changes in the display reading.

Monthly

This procedure describes a test to verify that the toxic gas transmitter responds properly to the target gas. It describes the test using a calibration kit that includes a calibration cup, calibration gas, sample tubing, and a fixed flow regulator with an on/off knob. See Table 3 on page 14 to determine the correct calibration cup and regulator for the required flowrate for your detector.

WARNING: Failure to use the recommended calibration cup and calibration gas flow

rate will result in an inaccurate reading.

NOTE: Perfor ming a r esp onse te st on t he toxic gas trans mitter ma y cause al arms. Be sur e

to put the controller into its calibration mode or disable external alarms before performing this test.

Preparing for the response test

1. Place the controller into its calibration mode or disable external alarms.

2. Verify that the controller display reading for the channel you are testing is 0 ppm. If the display reading is not 0 ppm, set the zero reading of the transmitter as described

in “Start Up” on page 8, then continue this procedur e.

3. Unscrew and remove the junction box cover.

4. Set a voltmeter to read in the millivolt (mV) range.

5. Plug the voltmeter leads into the test points on the amplifier. Plug the positive lead into the red + test point; plug the negative lead into the black - test point.

6. Use the following formula to determine the correct test points output for the test sample.

Output (mV) = (test sample/fullscale) X 400 + 100

For example, with a test sample of 0.5 ppm and a fullscale setting of 1.00 ppm, the correct output is 300 mV.

300 (mV) = (.50/1.00) X 400 +100

7. Unscrew the splashguard from the housing cap. Make su re the housing cap remains screwed firmly onto the housing body.

8. Screw the regulator into the calibration cylinder.

65-2340RKSS Toxic Gas Tr a nsm itter • 9

9. Use the sample tubing to connect the regulator to the calibration cup. Check the bottom of the calibration cup to see if it has a specified flow direction through the cup and if it does, make sure you connect the tube from the regulator to the inlet port. The 81-1138RK calibration cup, which is used for all detectors except for Cl2 and NH3 detectors, has a specified flow direction on the bottom of the cup. The 81-1138RK-CL2 and 81-1138RK-NH3 calibration cu ps do not have a specified flo w direction.

10. Push the calibration cup onto the plug-in sensor that sticks through the housing cap as far as it will go. The cup seals to the sensor with an O-ring. Make sure to use the correct calibration cup and sample flowrate for your detector.

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 two minutes, then verify that the reading is within ± 20% of the cylinder gas concentration.

NOTE: If the reading is not within ± 20% of the correct response reading, calibrate the

detector as described in “Calibration” on page 14.

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

4. Unscrew the regulator from the calibration cylind er.

5. Gently pull the calibration cup off of the plug-in sensor.

6. Screw the splashguard firmly back onto the housing cap.

7. Remove the voltmeter leads from the amplifier test points.

8. Reinstall the junction box cover.

9. When the controller display reading falls below th e alarm setpoints, return the controller to normal operation.

10. Store the components of the calibration kit in a sa fe place.

Quarterly

Calibrate the toxic gas transmitter as described in “Calibration” on page 14 of this manual.

Troubleshooting

The troubleshooting guide describes symptoms, probable causes, and recommended action for problems you may encounter with the toxic gas transmitter.

NOTE: This troubleshooting guide describes transmitter problems only. See the

controller operator’s manual for problems you may encounter with the controller.

10 • 65-2340RKSS Toxic Gas Transmitter

Table 2:Troubleshooting the Toxic Gas Transmitter

Condition Symptom(s) Probable Causes Recommended Action

Fail Condition • Controller indicates a

Slow or No Response/ Difficult or Unable to Calibrate

fail condition.

• Transmitter responds slowly or does not respond to response test.

• Unable to accurately set the zero or response reading during calibration.

• Transmitter requires frequent calibration.

Note: Under “normal” circumstances, the transmitter requires calibration once every 3 months.

Some applications may require a more frequent calibration schedule.

• The transmitter wiring is disconnected or misconnected.

• The plug-i n sensor is not properly plugged into the socket in the detector housing body.

• The transmitter’s zero reading is low enough to cause a fail condition.

• The transmitter is malfunctioning.

• The calibration cylinder is low, out-dated, or defective.

• The incorrect calibration cup or regulator is being used.

• The plug-i n sensor face is blocked w ith dirt or some other particulate contamination.

• The calibration gas is not an appr opriate concentration.

• The transmitter is malfunctioning.

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

2. Confirm that the plug-in sensor is installed properl y.

3. Perform a zero (fresh air) a djustmen t. A full calibration is recommended.

4. If the fail condition continues, replace the plug-in sensor as described later in this section.

5. 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. Confirm that yo u are using t he correct calibration cup and regulator for your detector type. See T able3 on page 14 for a list of t he required calibration cups and regulators.

3. Check the plug-in sensor face and remove any p articulate cont a mination if necessary.

4. Verify that the calibration gas concentration is appropriate for the transmitter. The concentration should be in the detection range, preferably about half of the detection range.

5. If the calibration/response difficulties continue, replace the plug-in sensor as described later in this section.

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

Replacing Components of the Toxic Gas Transmitter

This section includes a procedure to replace the plug-in toxic sensor, a procedure to replace the entire toxic detector assembly, and one to replace the amplifier. In most cases, it is not necessary to replace the entire detector assembly.

Replacing The Plug-in Toxic Sensor

CAUTION: The plug-in sensor contains electrolyte which is a dilute acid. Do not disassemble the

sensor when replacing it with a new one. If sensor electrolyte comes in contact with your skin, wash affected area thoroughly with soap and water.

1. Turn off the controller.

2. Turn off or unplug p ower to the controller.

3. Unscrew the detector housing cap with the spla shguard from the detector housing body. Mak e sure not to lose the cap gasket.

65-2340RKSS Toxic Gas Tr a nsm itter • 11

4. Unplug and remo ve the toxic sens or.

5. Carefully plug the replacement sensor into the connector that is located in the detector housing body.

WARNING: You must replace the plug-in sensor with the same type of sensor that is

installed. A detector cannot be converted from one type of detector to another by using a different plug-in sensor. For example, if you are replacing a Cl2 sensor, you must replace it with a Cl2 sensor.

6. Make sure the cap gasket is in place and screw the detector housing cap with the splashguard back onto the detector housing body.

7. Turn on power to the controller.

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

CAUTION: Allow the replacement se nsor to wa rm up for 5 minutes before you continue with the

next step.

9. Calibrate the detector as described in “Calibration” on page 14.

Replacing the Toxic Detector

NOTE: In most cases, it is only necessa r y to replace th e p lug- in sensor.

1. Turn off the controller.

2. Turn off or unplug p ower to the controller.

3. Remove the junction box cover.

4. Remove the detector terminal strip from its socket.

5. Disconnect the detector leads from the detector terminal strip. Note the position of the color-coded leads as you remove them.

6. Unscrew the detector from the junction box conduit hub.

7. 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. If necessary for environmental conditions, apply thread sealant or teflon tape to the hub and/or detector threads to seal them.

8. Connect the detector leads to the appropriate detector terminal strip terminals. Connect the black wire to the terminal labelled TOXIC - and the color coded wire to the terminal labelled TOXIC +. See Figure 4 on page 7 for the detector wiring connections to the amplifier and the detector wire color coding.

9. Reinstall the junction box cover.

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

11. Turn on the controller and place it into normal operation.

CAUTION: Allow the replacement detector to warm up for 5 minutes before y o u c o ntinue with

the next step.

12. Calibrate the replacement detector as described in “Calibration” on page 14.

12 • 65-2340RKSS Toxic Gas Transmitter

Replacing the Amplifier

1. Turn off the controller.

2. Turn off or unplug p ower to the controller.

3. Remove the junction box cover.

4. Unplug the detector terminal strip and controller terminal strip from their sockets. You may leave the wires connected to the terminal strips.

5. Unscrew and remove the screw with the flat and lock washers that secures the amplifier to the junction box.

6. Remove the old amplifier.

7. Install the new amplifier in to the junction box with the screw, lock washer, an d flat washer you removed in Step 5 above. A foam gasket that orients the amplifier and keeps it from rotating is installed on the bottom of the amplifier. Make sure the amplifier is seated flat in the junction box.

8. Install the detector and controller terminal strips into their socket s on the new amplifier as shown in Figu re 4 on page 7. If controller leads or detector leads were removed during this procedure, refer to Figure 4 on page 7 for the detector and amplifier connections.

NOTE: When a transmitter is first powered up with a new amplifier, the initial output

may be either high or below zero depending on the setting of the zero pot. Be sure to make arrangements so that this does not cause unwanted alarms.

9. Turn on power to the controller.

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

11. Allow the transmitter to warm-up for 5 minutes.

12. Calibrate the transmitter as described in “Calibration” on page 14 of this manual.

Calibration Frequency

Although there is no particular calibration frequency that is correct for all applications, a calibration frequency of every 3 months is adequate for most toxic gas transmitter applications. Unless experience in a particular application dictates otherwise, RKI Instruments, Inc. recommends a calibration frequency of every 3 months for the toxic gas transmitter.

If an application is not very demanding, for example detection in a clean, temperature controlled environment where toxic gas 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 the environment is not well controlled or if toxic gas is often present, then more frequent calibration than every 3 months may be necessary.

65-2340RKSS Toxic Gas Tr a nsm itter • 13

Calibration

This section describes how to calibrate the toxic gas transmitter. It includes procedures to prepare for calibration, set the zero (fresh air) reading, set the span (response) reading, and return to normal operation. It describes calibration using a calibration kit that includes a calibration cup, calibration gas, sample tubing, and a fixed flow regulator with an on/off knob. The required sample flow rate and calibration cup depend on the transmitter being calibrated. Table 3 below lists the required calibration cups and regulators for the various toxic gas transmitters.

Table 3: Required Calibration Cups and Flow Rates

Required Regulator/

Flowrate for Calibration

Gas

Yes

Transmitter Type

Arsine (AsH

Required

Calibration Cup

) 81-1138RK 81-1051RK, 0.5 LPM (liters

per minute)

Chlorine (Cl

), 0 - 3.00 ppm

81-1138RK-CL2 81-1051RK, 0.5 LPM No

and 0 - 10.0 ppm Hydrogen Cyanide (HCN) 81-1138RK-HCN 81-1051RK, 0.5 LPM Yes Ammonia (NH

Phosphine (PH Sulphur Di oxide (SO

) 81-1138RK-NH3 81-1051RK-25, 0.25 LPM No

) 81-1138RK 81-1051RK, 0.5 LPM Yes

W ARNING: Not using the recommended calibration cup, sample flowrate, and specified

flow direction (for 81-1138RK calibration cup only) will result in an inaccurate calibration. Make sure to use the calibration cup and sample flow rate listed in Table 3 for your target gas when performing a calibration. Also make sure to connect the sample tubing to the calibration cup port that results in the specified flow direction for the 81-1138RK calibration cup.

Flow Direction

Specified on

Calibration Cup

Prepari ng for Ca libration

1. Place the controller into its calibration mode or disable external alarms.

2. Unscrew and remove the junction box cover.

3. Set a voltmeter to measure in the millivolt (mV) range.

4. Plug the voltmeter leads into the test points on the amplifier. Plug the positive lead into the red + test point; plug the negative lead into the black - test point.

5. Use the following formula to determine the correct test points output for the calibrating sample.

Output (mV) = (calibrating sample/fullscale) X 400 + 100

14 • 65-2340RKSS Toxic Gas Transmitter

For example, with a calibrating sample of .50 ppm and a fullscale setting of

1.00, the correct output is 300 mV.

300(mV) = (.50/1.00) X 400 +100

NOTE: Calibrating the toxic gas transm itter may cause alarms. Be sure to put the

controller into its calibration program or disable external alarms before continuing.

6. Unscrew the splashguard from the detector housing cap. Make sure the cap remains securely screwed onto the housing body.

7. Push the calibration cup onto the plug-in sensor tha t sticks through the housing cap. The calibration cup seals to the sensor with an O-ring.

Setting the Zero (Fresh Air) Reading

NOTE: If you can verify that the toxic gas transmitter is in a f resh air environment, you

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

1. Screw the regulator into the zero air calibration cylinder.

2. Use the sample tubing to connect the regulator to the calibration cup. Make su re to connect the tube to the inlet side of the calibration cup if using the 81-1138RK calibration cup which is marked on the outside bottom to show the required flow dire ction t hrough the cup.

3. Turn the regulator knob counterclockwise to open the regulator.

4. Allow the gas to flow for two minutes and verify a reading of 100 mV (±2 mV). If necessary, use the zero pot on the amplifier to adjust the reading to 100 mV (±2 mV).

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

6. Unscrew the regulator from the zero air calibration cylinder. Leave the sample tubing connected to the regulator and the calibration cup.

NOTE: Depending on the size of your zero air cylinder, it is possible that you will have a

different regulator for the zero air cylinder and toxic gas cylinder. If necessary to fit the calibration toxic gas cylinder, change the regulator.

Setting the Span (Response) Reading

1. Screw the regulator into the calibration cylinder. Verify that the calibration gas is representative of the transmitter’s target gas.

2. Turn the regulator knob counterclockwise to open the regulator.

3. Allow the calibration gas to flow for two minutes and verify that the reading matches the response reading (±2 mV) you determined ea rlier. If necessary, use the span pot on the amplifier to adjust the reading to match the correct response reading.

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

5. Unscrew the regulator from the calibration cylinder and gently pull the calibration cup off of the plug-in sensor.

65-2340RKSS Toxic Gas Tr a nsm itter • 15

Returning to Normal Operation

1. Remove the voltmeter leads from the amplifier test points.

2. Gently pull the calibration cup off of the plug-in sensor

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

sample tubing.

3. Screw the splashguard firmly back onto the housing cap.

4. Secure the junction box cover to the junction box.

5. When the controller display reading falls below th e alarm setpoints, 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.

6. Verify that the controller display reading decreases and stabilizes a t 0 ppm.

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

Parts List

Part Number Description

06-1283RK Calibration kit sample tubing, 3 foot teflon w/flexible tubing on ends 07-0125RK Detector housing cap gasket 07-7151RK O-ring for junction box 10-5153RK Lid locking set screw for junction box 18-0416RK-11 Junction box with cover, stainless steel 57-1064RK-03 S2 series toxic amplifier 65-2300RK-ASH3 Replacement detector assembly, AsH

65-2300RK-CL2 Replacement detector assembly, Cl

65-2300RK-CL-10 Replacement detector assembly, Cl2 , 0 - 10.0 ppm range

65-2300RK-HCN Replacement detector assembly, HCN (includes plug-in sensor)

Table 4 lists replacement parts and accessories f or the toxic gas transmitter.

Table 4: Parts List

(includes plug-in sensor)

, 0 - 3.00 ppm range

(includes plug-in sensor)

65-2300RK -NH3 Replacement detector assembly, NH3 (includes plug-in sensor) 65-2300RK-PH3 Replacement detector assembly, PH 65-2300RK-SO2 Replacement detector assembly, SO

16 • 65-2340RKSS Toxic Gas Transmitter

(includes plug-in sensor)

Table 4: Parts List

Part Number Description

71-0302RK 65-2340RKSS Operator’s Manual (this document) 81-0076RK Zero air calibration cylinder, 17 liter steel 81-0076RK-01 Zero air calibration cylinder, 34 liter steel 81-0076RK-03 Zero air calibration cylinder, 103 liter steel 81-0170RK-02 Calibration cylinder, 5 ppm SO

81-0170RK-04 Calibration cylinder, 5 ppm SO 81-0175RK-02 Calibration cylinder, 10 ppm NH 81-0175RK-04 Calibration cylinder, 10 ppm NH

in nitrogen, 58 liter aluminum

in nitrogen, 34 liter aluminum

in nitrogen, 58 liter aluminum

in nitrogen, 34 liter aluminum

81-0185RK-02 Calibration cylinde r, 0.5 ppm PH3 in nitrogen, 58 liter aluminum, used to calibrate

and AsH3 detectors, see conversion factor on AsH3 plug-in sensors

81-0185RK-04 Calibration cylinde r, 0.5 ppm PH3 in nitrogen, 34 liter aluminum, used to calibrate

and AsH3 detectors, see conversion factor on AsH3 plug-in sensors

81-0190RK-02 Calibration cylinder, 5 ppm Cl 81-0190RK-04 Calibration cylinder, 5 ppm Cl 81-0192RK-02 Calibration cylinder, 2 ppm Cl 81-0192RK-04 Calibration cylinder, 2 ppm Cl

in nitrogen, 58 liter

in nitrogen, 34 liter

in nitrogen, 58 liter, aluminum

in nitrogen, 34 liter aluminum

81-0196RK-02 Calibration cylinder, 10 ppm HCN in nitrogen, 58 liter aluminum 81-0196RK-04 Calibration cylinder, 10 ppm HCN in nitrogen, 34 liter aluminum 81-1050RK Regulator with gauge and knob, 0.5 LPM, for 17 liter and 34 liter steel calibration

cylinders (used for 34 liter zero air cylinder only)

81-1051RK Regulator with gauge and knob, 0.5 LPM, for 34AL/58/103 liter calibration

cylinders

81-1051RK-25 Regulator with gauge and knob, 0.25 LPM, for 34AL/58/103 liter calibration

cylinders (used to calibrate NH

81-1138RK Calibration cup, general (SO

toxic detector only)

), for ESM-01, use 0.5 LPM flow

81-1138RK-CL2 Calibration cup, for ESM-01 Cl2, use 0.5 LPM flow 81-1138RK-NH3 Calibration cup, for ESM-01 NH3, use 0.25 LPM flow 81-F503RK Calibration kit, includes regulator, calibration cup, and a 58 liter 10 ppm NH