RKI Instruments 65-2394RK-CH4-4 User Manual
65-2394RK-CH4-4
Combustible Gas Transmitter
Part Number: 71-0277RK
Revision: P1
Released: 4/9/13
Operator’s Manual
RKI Instruments, Inc.
www.rkiinstruments.com
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.
65-2394RK-CH4-4 Combustible 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 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.
65-2394RK-CH4-4 Combus tible G a s Tr ans mitter
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Combustible Gas Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Calibration Cup/Splash Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Amplifier Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Detector Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting the Combustible Gas Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wiring the Detector to the Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring the Amplifier to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing Components of the Combustible Gas Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Determining Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
65-2394RK-CH4-4 Combustible Gas Transmitter
Overview
This manual describes the 65-2394RK-CH4-4 combustible gas transmitter. This manual
also describes how to install, s tart up, configure, maintain, and calibrate 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 the combustible gas transmitter.
Target Gas 65-2394RK-CH4-4: Methane (CH4)
Area Classification Explosionproof for Class I, Groups B, C, and D
Sampling Method Diffusion
Signal Output 4 to 20 mA
Table 1:Specifications
Description Specification
Detection Range 0 to 100% LEL
Response Time 90% in 45 seconds
Operating Temperature -4°F to 122°F (-20°C to 50°C)
Accuracy ± 5% of reading or ± 2% of full scale (whichever is gr eater)
WARNING : When using the 65-2394RK-CH4-4, you must follow the instructions and
warnings in this manual to assure proper and safe opera tion of the
65-2394RK-CH4-4 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 65-2394RK-CH4-4 as described in
this manual.
65-2394RK-CH4-4 Com bus tible Ga s Tr a nsm itter • 1
Description
GWRB
Sens or
Current
m A
SPAN
ZERO
Amplifier
Factory Adjust
Pot
57-1053RK
S
S2 001
Jumper Pins,
Factory U se
Only
Detector T erm inal
Stri p
- Test Point
+ Test Poi nt
ZeroPot
Span P ot
Factory Adjust Pot
TerminalStrip
IR LEL D etector
Detector J-Box
Amplifier J-Box
LEL PWR / SIG
Calibration Cup/Splash G uard
Controller Terminal
Strip
The 65-2394RK-CH4-4 combustible gas transmitter utilizes an infrared type of detector
which has some advantages over a catalytic type of combustible detector. The infrared
detector will generally have a long er 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 combustible gas detector, calibration
cup/splash guard, amplifier, the amplifier junction box, and the detector junction box.
The two junction box configuration is intended for situations where the detector needs to
be installed at an inaccessible location. The detector junction box can be installed at the
inaccessible location and the amplifier junction box can be installed in a more readily
accessible area.
Figure 1: Combustible Gas Transmitter Component Location
2 • 65-2394RK-CH4-4 Combustible Gas Transmitter
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” NPT thr eads
on each end and a 1 1/4” hex that allows removal or installation of the detector with a
wrench. A por ous flame arr e stor t hat is coat ed wit h a hydr o phobic f ilm that re pels liquids
is on one end of the detector and al lows samp le gas to enter the detector. Four color coded
leads, red, white, green, and black, extend from the other end of the detector. The leads
allow you to connect the detector to the amplifier.
Calibration Cup/Splash Guard
A calibration cup/splash guard is installed on the IR LEL detector. A fitting at the bottom
of the calibration cup/splash guard allows a length of tubing to be connected for
calibration and routed to a more easily accessible location. The calibration cup/splash
guard also protects the detector.
Amplifier
The amplifier is located in the amplifier junction box. The amplifier converts the electrical
output from the detector to a 4 to 20 mA signal that corresponds to th e detection range
and transmits the signal to a gas monitoring controller. A foam gasket that orients the
amplifier and keeps it from rotating is installed on the bottom of the amplifier. A label on
the amplifier indicates the detector drive current. This drive current is factory set and is
dictated by the combustible gas to which the detector is calibrated. Consult RKI
Instruments, Inc. if you plan to change the calibration gas for the transmitter, for example
from a methane calibration to a hexane calibration. The amplifier includes the detector
terminal strip, controller terminal strip, span pot, zero pot, and test points (see Figure 1).
Controller Terminal Strip
The controller terminal strip is a three position plug-in style terminal strip located near the
top of the amplifier. Use the controller terminal strip to wire the combustible gas
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. Use the detector terminal strip to connect the IR LEL detector to
the amplifier.
NOTE: See “Wiring the Detector to the Amplifier” 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 gas response and counterclockwise to decrease the gas response.
65-2394RK-CH4-4 Com bus tible Ga s Tr a nsm itter • 3
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