RKI Instruments 65-2390RK-HC, 65-2390RK-CH4 User manual

65-2390RK

Combustible Gas Transmitter

Operator’s Manual

Part Number: 71-0119RK
Revision: A
Released: 4/12/11

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WARNING

Read and understand this instruction manual before
operating transmitter. Improper use of the transmitter could
result in bodily harm or death.

Periodic calibration and maintenance of the transmitter is
essential for proper operation and correct readings. Please
calibrate and maintain this tra nsmitt er regula rly! Frequency
of calibration depends upon the type of use you have and
the sensor types. Typical calibration frequencies for most
applications are between 6 and 12 months, but can be
required more often or less often based on your usage.

65-2390RK Combustible Gas Transmitter

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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 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 assum e i ndemnification for any accident or damage caused by the op e r a t ion of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.

65-2390RK Combustible Ga s Tr ans mitte r

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Table of Contents

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

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

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

IR LEL Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Mounting the Combustible Gas Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wiring the Combustible Gas Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

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

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

65-2390RK Combustible Gas Transmitter

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Overview

This manual describes the 65-2390RK combustible gas transmitter. This manual also
describes how to install, start up, con fi gure, mainta in, a nd ca librate the transmitter 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 combustible gas transmitter.

Specifications

Table 1 lists specifications for th e combustible gas transmitter.

Table 1:Specifications

Target/Calibration Gas 65-2390RK-CH4: Methane (CH

65-2390RK-HC: Propane

Area Classification Explosionproof for Class I, Groups B, C, and D
Sampling Method Diffusion
Signal Output 4 to 20 mA
Detection Range 0 to 100% LEL
Response Time 90% in 45 seconds
Accuracy ± 5% of reading or ± 2% of full scale (which ever is greater)

)

4

W ARNING: When using the 65-2390RK, you must follow the instructions and warnings

in this manual to assure proper and safe operation of the 65-2390RK and to
minimize the risk of personal injury. Be sure to maintain and period ically
calibrate the 65-2390RK as described in this manual.

65-2390RK Combustible Gas Transm itter • 1

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Description

Interconnect Terminal Strip

The 65-2390RK combustible gas transmitter has two versions, the 65-2390RK-CH4 which
is calibrated to methane and the 65-2390RK-HC which is calibrated to propane. The
transmitter utilizes an infrared type of detector which has some a dvantages over a
catalytic type of combustible detector. The infrared detector will generally have a longer
service life than a catalytic detector, it will require calibration less often, and it can detect
combustible gas even if there is no oxygen in the sample which allows detection of
combustible gas in an inert atmosphere.

This section describes the components of the combustible gas transmitter. The transmitter
is a 4 - 20 mA type detector head. It consists of the infrared LEL detector, amplifier, and
junction box.

FactorySet Pots

J-Box

100-500 mV Range

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 that is coated with a hydrophobic film
that repels liquids is on one end of the detector and allows sample gas to enter the
detector . Four color coded leads, r ed, white, green , and black, extend fr om the other end of
the detector. The leads allow you to connect the detector to the amplifier.

Amplif ier

GND
24V
4/20

POWER/SIGSENSOR

TP +

RED
WHT
GRN
BLK

TP -

Test Points

Jumper Pins for

Factory Use Only

Span Pot

Zero Pot

IR LEL Detector

Figure 1: Combustible Gas Transmitter Component Location

To distinguish the propane detector from the methane detector (in case the replacement
sensor label that is applied to one of the leads is lost), a short length of red shrink tubing is

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applied to the white wire of the propane detector near where the wire comes out of the
nipple.

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.
The amplifier includes the interconnect terminal strip, span potentiometer, zero
potentiometer, and test points (see Figure 1).

Interconnect Terminal Strip

The interconnect terminal strip is a seven-point terminal strip. Use the interconnect
terminal strip to connect the IR LEL detector to the amplifier and the amplifier to a
controller.

NOTE: The IR LEL detector is factory-wired to the amplifier. See the Installation section

of this manual for all wiring procedures related to the transmitter.

Span Potentiomete r

The span potentiometer is near the bottom of the amplifier (see Figure 1). Use the span
potentiometer to adjust the transmitter’s response output during the calibration
procedure. Turn the adjustment screw clockwise to increase the gas response and
counterclockwise to decrease the gas response.

Zero Potentiometer

The zero potentiometer is to the right of the span potentiometer (see Figure 1). Use the
zero potentiometer to adjust the transmitter’s target gas-free 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.

CAUTION: The amplifier includes two additional potentiometers. They are factory-set. Do not

adjust them.

Test Points

The test points (labeled TP+ and TP-) are to the left of the interconnect terminal strip
(see Figure 1). The test points produce a 100 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
transmitter’s output during the start-up and calibration procedures.

Junction Box

Use the junction box to install the comb ustible gas transmitter at a mounting site that is
remote from the controller. The junction box also protects th e amplifi er and wiring
connections made to the amplifier. Use the two 3/4 in. conduit hubs to mount the detector
to the junction box (bottom hub) and connect wiring from the amplifier to the controller
(top hub).

NOTE: The detector and amplifier are factory-mounted to the junction box.

Use the junction box’s two mountin g holes to mount the combustible gas transmitter to a
vertical surface at the monitoring site. Use the cover on the front of the junction box to
access the interior of the junction box.

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Installation

)

This section describes procedures to mount the combustibl e gas transmitter in the
monitoring environment and wire the transmitter to a controller.

Mounting the Combustible 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. For lighter gases,

mount the detector near the ceiling; for heavier gases, mount the detector near the
floor.

6.1

1.1

3.94

5.2

2.75

5.46

IR LEL Detector

Figure 2: Mounting the Combustible Gas Transmitter

Ø.25MoutingHoles (2X

3/4" NPT Conduit Hub

1.9 max

7.3 max

If the detector is mounted to the junction box, skip to step 5. If not, continue with step 2.

2. Remove the junction box cover.

3. Guide the four wires that extend from the top of the detector through the bottom
conduit hub of the junction box.

4. Screw the detector into the bottom conduit hub of the junction box.

5. At the monitoring site, use #10 screws through the junction box’s two mounting holes
to secure the junction box to a vertical surface.

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CAUTION: Mount the combustible gas trans mitte r wi th th e d etector f aci ng down (see F igure 2.)

Wiring the Combustible Gas Transmitter to a Controller

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

wiring connections.

1. Turn off power to the controller.

2. Place the controller’s power switch in the OFF position.

3. Remove the junction box cover.

4. Verify that the detector leads are wired to the amplifier’s interconnect terminal strip.
If necessary, connect the detector leads to the interconnect terminal strip as shown in
Figure 3.

5. Guide a three-conductor, shield ed cable or three wires in conduit through the top
conduit hub of the junction box.

6. Connect the three wires to the interconnect terminal strip as follows (see Figure 3).

• Connect the positive wire to the 24VDC terminal.

• Connect the feedback wire to the 4-20 (FB) terminal.

• Connect the negative wire to the GND (DC -) terminal.

CAUTION: If shielded cable is used, leave the cable s hie ld’s drain wire insulate d and

disconnected at the transmitter. You will connect the opposite end of the cable’s drain
wire at the controller to chassis ground.

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

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

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

power cable may disrupt the transmission of the transmitter signal to the
controller.

9. Connect the wires to the applicable transmitter terminal strip at the controller as
shown in Figure 3 below.

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J-Box

e

Cable S hi eld

- (DC Ground)
+ 24 V DC

4 - 20 mA In (FB)

Amplifi er

GND
24V
4/20

POWER/SIGSENSOR
RED
WHT
GRN
BLK

Controller or

Recor di ng Dev i c

Red
White

IR LEL Detector

Black

Green

Figure 3: Wiring the Combustible Gas Transmitter to a Controller

10. If shielded cable is used, connect the cable’s drain wire to an available chassis ground
at the controller.

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Start Up

This section describes procedures to start up the combustible gas transmitter and place th e
transmitter 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 or plug in power to the controller, then place the contr oller’s power switch in
the ON position.

4. Verify that the controller is on and operating properly. Refer to the controller
operator’s manu al.

NOTE: When first powered up, the transmitter will enter about a one minute period

when the 4-20 mA output is stab ilizing and may be above the controller alarm
points or well below zero momentarily. RKI controllers have a one minute
warmup period when the controller does not display any gas reading or give any
alarm indication. The combustible gas transmitter’s 4-20 mA signal should be
stable by the time the controller’s warmup period is over.

CAUTION: Allow the detector 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 combustible gas in the monitoring en vironment, use

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

1. Verify that the transmitter is in a fresh air environment (environment known to be free
of combustible and toxic gases and of normal oxygen content, 20.9%).

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 test point labeled TP+; plug the ne gative lead into the test point labeled TP-.

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

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

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

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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 transmitter. It includes daily, monthly, and biannua l
procedures.

Daily

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

Monthly

This procedure describes a test to verify that the combustible gas transmitter 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 combustible transmitter 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 for the cha nnel you are testing is 0 %LEL.
If the display reading is not zero, set the zero reading of the transmitter as described

in “Start Up” on page 7 of this manual, then continue this procedure.

3. Screw the calibration cup onto the bottom of the combustible detector.

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

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

6. Remove the junction box cover, then plug the voltmeter leads into the test points on
the amplifier.

Plug the positive lead into the test point labeled TP+; plug the negative lead into the
test point labeled TP-.

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

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

For example, with a test sample of 50% LEL and a fullscale setting of 100% LEL, the
correct output is 300 mV.

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

Performing the response test

1. Screw the regulator into the calibration cylinder.

2. Turn the regulator knob coun terclockwise to open the regulator.

3. Allow the gas to flow for one minute.

4. Verify that the reading is within ± 20% of the response reading you determined earlier.

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

transmitter as described in “Calibration” on page 13 of this manual.

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

6. Unscrew the regulator from the calibration cylind er.

7. Unscrew the calibration cup from the detector.

8. Remove the voltmeter leads from the amplifier test poin ts.

9. Reinstall the junction box cov er.

10. When the controller display reading falls below the alarm setpoints, return the
controller to normal operation.

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

Biannually

Calibrate the combustible gas transmitter as described in “Calibration” on page 13 of this
manual.

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Troubleshooting

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

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

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

Table 2:Troubleshooting the Combustible 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
six months.

Some applications
may require a more
frequent calibration
schedule.

• The transmitter wiring
is disconnected or
misconnected.

• 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 transmitter is
malfunctioning.

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

2. Calibrate the transm itt er.

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 regulator used for
calibration is a 0.5 LPM regulator.

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

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

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Replacing Components of the Combustible Gas Transmitter

This section includes procedures to replace the IR LEL detector and amplifier.

Replacing the IR LEL Detector

1. Turn off power to the controller.

2. Place the controller’s power switch in the OFF position.

3. Remove the junction box cover.

4. Disconnect the detector leads from the interconnect terminal strip. 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 interconnect terminal strip as shown in Table 3
below and Figure 3 on page 6 of this manual.

Table 3: Reconnecting the Combustible Gas

Detector to the Amplifier

Detector Lead

Red RED

White WHT

Green GRN

Black BLK

Amplifier Interconnect

Terminal Strip

8. Turn on power to the controller.

9. Place the controller’s power switch in the ON position .

NOTE: When first powered up, the transmitter will enter about a one minute period

when the 4-20 mA output is stab ilizing and may be above the controller alarm
points or well below zero momentarily. RKI controllers have a one minute
warmup period when the controller does not display any gas reading or give any
alarm indication. The combustible gas transmitter’s 4-20 mA signal should be
stable by the time the controller’s warmup period is over.

CAUTION: Allow the replacement detector to warm up for 5 minutes befor e y o u c ontinue with

the next step.

10. Calibrate the replacement detector as described in “Calibration” on page 13 of this
manual.

Replacing the Amplifier

1. Turn off power to the controller

2. Place the controller’s power switch in the OFF position.

3. Remove the junction box cover.

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4. Disconnect the detector leads from the inte rconne c t terminal strip.

5. Disconnect the wiring that connects the combustible gas transmitter to the controller
from the amplifier’s interconnect terminal strip.

6. Unscrew and remove the two screws that secure the amplifier to the junction box.
The screws are at the top left and bottom right of the amplifier.

7. Remove the amplifier.

8. Place the new amplifier in the same position as the amplifier you removed in the
previous step.

9. Use the two screws you removed in step 6 to secure the amplifier to the junction box.

10. Reconnect the wiring that connects the controller to the combustible gas transmitter at
the amplifier’s interconnect terminal strip as shown in Table 4 below and Figure 3 o n
page 6 of this manual.

Table 4: Reconnecting the Combustible Gas Amplifier

to the Controller

Amplifier Interconnect

T erminal Strip

GND - (DC -)

4-20 4 - 20 mA (FB or S)
24V + 24V

Controller

Transmitter Terminal

Strip (typical)

11. Reconnect the detector leads to the amplifier’s interconnect terminal strip as shown in
Table 5 below and Figure 3 on page 6 of this manual.

Table 5: Reconnecting the Combustible Gas

Detector to the Amplifier

Detector Lead

Red RED

White WHT

Green GRN

Black BLK

Amplifier Interconnect

Terminal Strip

12. Turn on power to the controller.

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

NOTE: When first powered up, the transmitter will enter about a one minute period

when the 4-20 mA output is stab ilizing and may be above the controller alarm
points or well below zero momentarily. RKI controllers have a one minute
warmup period when the controller does not display any gas reading or give any
alarm indication. The combustible gas transmitter’s 4-20 mA signal should be
stable by the time the controller’s warmup period is over.

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CAUTION: Allow the detector to warm up for 5 minutes before you continue with the next step.

14. Calibrate the combustible gas transmitter as de scribed in “Calibration” on page 13 of
this manual.

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 gas
transmitter applications. Unless experience in a particular application dictates otherwise,
RKI Instruments, Inc. recommends a calibration frequency of every 6 months for the
infrared combustible gas transmitter.

If an application is not very demanding, for example detection in a clean, temperature
controlled environment where the toxic or co mbustible tar get gas is not normally pr esen t,
and calibrati on adjustments are mini mal at calibration, then a calibration frequ ency 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 transmitter. 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.

Prepari ng for Ca libration

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

2. Use the sample tubing that comes with the calibration kit to connect the regulator to
the calibration cup.

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

4. Remove the junction box cover, then plug the voltmeter leads into the test points on
the amplifier.

Plug the positive lead into the test point labeled TP+; plug the negative lead into the
test point labeled TP-.

65-2390RK Combustible Gas Transm itter • 13

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

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

For example, with a calibrating sample of 50% LEL and a fullscale setting of
100% LEL, the correct output is 300 mV.

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

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

NOTE: Calibrating the combustible transmitter may cause alarms . Be sure to put the

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

Setting the Zero Reading

CAUTION: If you can verify that the combustible transmitter is in a fresh air environment, you

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

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

2. Turn the regulator knob coun terclockwise to open the regulator.

3. Allow the gas to flow for one minute and verify a reading of 100 mV (±2 mV). If
necessary, use the zero potentiometer on the amplifier to adjust the reading to 100 mV
(±2 mV).

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

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

Setting the 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 coun terclockwise to open the regulator.

3. Allow the calibration gas to flow for one minute and verify that the reading matches
the response reading (±2 mV) you determined earlier. If necessary, use the span
potentiometer 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 cylind er.

Returning to Normal Operation

1. Remove the voltmeter leads from the amplifier test poin ts.

2. Unscrew the calibration cup from the detector.

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

sample tubing.

3. Secure the junction box cover to the junction box.

4. When the display reading falls below the ala r m setpoints, return the controller to

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Parts List

normal operation.

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

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

Table 6 lists replacement parts and accessories for the combustible gas transmitter.

Table 6:Parts List

Part Number Description

06-1248RK Sample tubing (3/16 in. x 5/16 in.; specify length when ordering)
18-0405RK-01 Junction box (without cover; pre-drilled for amplifier)
18-0406RK Junction box cover (cover only)
57-1050RK Amplifier (specify detector part number when ordering)
61-0190RK-CH4 Methane infrared LEL detector
61-0190RK-HC HC infrared LEL detector (calibrated to propane)
65-2390RK-CH4 Methane transmitter (includes detector, junction box, and amplifier)
65-2390RK-HC Propane transmitter (includes detector, junction box and amplifier)
71-0119RK 65-2390RK Combustible Gas Transmitter Operator’s Manual (this document)
81-0004RK-01 Calibration cylinder (50% LEL propane; 34-liter)
81-0012RK-01 Calibration cylinder (50% LEL Methane; 34-liter)
81-0076RK-01 Zero air calibration cylinder (34-lite r )
81-1050RK Regulator , 0 .5 liter/minute, with gauge and kn ob, for 17- and 34-liter calibration

cylinders
81-1103RK Calibration cup
82-0006RK Pot adjust screwdriver, for calibration

65-2390RK Combustible Gas Transm itter • 15

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