RKI Instruments 65-2405RK-05 User manual

Combustible Gas Transmitter

Part Number: 71-0180RK
Revision: 0

65-2405RK-05

Operator’s Manual

Released: 2/16/11

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.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 detect or 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 are b etween
3 and 6 months, but can be required more often or less often
based on your usage.

65-2405RK-05 Combustible Gas Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

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 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 no r mal 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 th e operator’s manual. This warranty indicates
the full extent of our liability , a nd we are not responsible for r emoval or replacement costs,
local repair costs, transportation costs, or contingent expenses incurred without our prior
approval.

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.

a) Absorbent cartridges d) Batteries
b) Pump diaphragms and valves e) Filter elements
c) Fuses

This warranty covers instruments and parts sold to users by authorized distributors,
dealers, and representatives as appointed by RKI Instruments, Inc.

We do not assume indemnification for a ny accident or damage ca u s e d by the operation of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.

65-2405RK-05 Combus tible G a s Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

Table of Contents

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

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

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

Combustible Gas 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Replacing Components of the Combustible Gas Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

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

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

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

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

65-2405RK-05 Combustible Gas Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

Overview

This manual describes the 65-2405RK-05 combustible gas transm itter. This manual also
describes how to install, start up, configure, maintain, and calibrate the transmitter w hen
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

WARNING: Do not use this product in a manner not specified in this manual.

Table 1 lists specification s for the combustible gas transmitter.

Table 1:Specifications

Description Specification

Target Gas

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
Accuracy ± 5% of reading or ± 2% LEL (whichever is greater)
Response Time 90% in 45 seconds
Operating Temperature

1

If calibration to a combustible gas other than methane is required, specify the required

calibration gas at time of order.

Combustible gas, methane calibration standard

-40°F to 167°F (-40°C to 75°C)

1

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

documentation for installation instructions:

!

WARNING: When using the 65-2405RK-05, you must follow the instructions and

warnings in this manual to assure proper and safe operation of the
65-2405RK-05 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 65-2405RK-05 as described in this
manual.

65-2405RK-05 Combustible Ga s Tr a nsm itter • 1

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

Description

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, amplifier, and
junction box.

Factory Adjust Pot

Span Pot

Zero Pot

Factory Adjust Pot

Ju mp er Pins,

Factory Use Only

+ Test Point

- Test Point

Controller Terminal Strip

Amplifier

SPAN

ZERO

Sensor

Current

mA

SBR

PWR / SIG

S2 001

57-1053RK

G

LEL

W

Detector Terminal Strip

J-Box

Reducing Bushing,

3/4 NPT to 1/2 NPT

Figure 1: Combustible Gas Transmitter Component Location

Combustible Gas Detector

The combustible gas 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 arrest or al so co ntai n s any s park s whi ch may occur within the detector. The 1/2
inch NPT mounting threads at the top of the detector allow you to mount it into the
bottom conduit hub of the junction box. A flame arrestor guard is located at the bottom of
the detector and is permanently bonded to the detector housing. The flame arrestor guard
protects the flame arrestor from impact damage. Four color-coded leads extend from the
top of the detector. The leads allow you to connect the detector to the amplifier.

2 • 65-2405RK-05 Combustible Gas Transmitter

LEL Detector

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

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 .
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 e xample 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 . U se the contro ller 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. Use the detector terminal strip to connect the detector to the
amplifier.

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

Combustible Gas Transmitter to a Controller” on page 5 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 ad just the amplifier’s
zero (fresh air) output during the start-up and calibration pro cedures.

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.

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

adjust them.

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

Use the junction box to install the transm itter at a mounting site that is remote from the
controller. The junctio n bo x protects the amplifier and wirin g connections made to the
amplifier. Use the top 3/4’’ conduit hub to connect wiring from the amplifier to the
controller. Use the cover on the front of the junction box to access the interior of the
junction box. The detector and amplifier are factory installed in th e junc tion box. Three
spacers installed on the back of the junction box control the distance of the junction box

65-2405RK-05 Combustible Ga s Tr a nsm itter • 3

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

Installation

from a mounting surface and ensure that there is enough room to install a calibration cup
on the detector during calibration.

This section describes procedures to mount the combustible 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.

3/4 NPT Female

2.70 .38

3.65

7.5 MAX
Rubber

Spacer,
3X

J-Box

3/4 x 1/2

Reduci ng Bus hing

LEL Detector

.75

Figure 2: Mounting the Combustible Gas Transmitter

2. At the monitoring site you select, hang or mount the junction box with the detector
facing down (see Figure 2).

4 • 65-2405RK-05 Combustible Gas Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

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 the controller.

2. Turn off or unplug power to the controller.

3. Remove the junction box co ver.

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 3.

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

WARN IN G: To maintain the explosion proof classification of the detector/junction box

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

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

7. Pull out the controller terminal strip, and connect the three wires to the terminal strip
as follows (see Figure 3).

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

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

• Connect the negative wire to the PWR/SIG “-” terminal.

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

insulated at the transmitter. You will connect the opposite 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 combustible 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 tra n smission of the transmitter signal to the
controller.

11. Connect the wires to the applicable detector/transmitter terminal strip at the
controller as shown in Figure 3 .

65-2405RK-05 Combustible Ga s Tr a nsm itter • 5

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

Cable Shield

+ 24 VDC
4 - 20 mA In (S)

- (D C Ground)

J-Box

Controller or

Recordin g Device

Amplifier (Transmitter)

S

PWR / SIG

B

LEL

W GR

Black
Green
White
Red

Detector Wires

LEL Detector

Figure 3: Wiring the Combustible 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.

6 • 65-2405RK-05 Combustible Gas Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

Start Up

This section describes procedures to start up the combustible gas transmitter and place the
transmitter into normal operation.

Introducing Incoming Power

1. Complete the installation procedures described earlier in this manual.

2. Verify that the po wer 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. Ve rify that the controller is on and operating properly. Refer to the controller
operator’s manu al.

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

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 combustible ga s in the monitoring environm ent, use

the calibration kit and the zero air calibration cylinder to introduce “fresh air” to the
detector and verify an accurate zero setting. See “Calibration” on page 13 for
instructions to apply zero air when setting the zero signal.

1. V erify that the transmitter is in a fresh air environment (environment known to be free
of combustible 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. P lug 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 fla t-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.

65-2405RK-05 Combustible Ga s Tr a nsm itter • 7

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

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 quarterly
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

NOTE: Performing a response test on the combustible gas transmitter may cause alarms.

test procedure.

Be sure to put the controller into its calibration mode 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 length of sample tubing.

Preparing for the response test

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

2. Ve rify that the controller display reading for the channel you are testing is 0 %LEL.
If the display reading is not 0 %LEL, set the zero reading of the transmitter as

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

WARNING: Do not remove the junction box cover while the circuits are energized

unless the area is determined to be non-hazardous. Keep the junction box
cover tightly closed during operation.

3. Unscrew and remove the junction box cover.

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

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

8 • 65-2405RK-05 Combustible Gas Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

6. 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

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

8. Screw the regulator into the calibration cylinder.

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

Performing the response test

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

2. Allow the gas to flow for one minu te, then 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.

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

4. Unscrew the regulator from the calibration cylinder.

5. Unscrew the calibration cup from the detector.

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

7. Reinstall the junction box cover.

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

9. Store th e components of the calibration kit in a safe place.

Quarterly

Calibrate the combustible gas transmitter as described in “Calibration” on page 13 of this
manual. See the calibration frequency discussion in “Calibration Frequency” on page 12 to
determine if a quarterly calibration schedule fits your needs.

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 m ay encounter with the
controller.

65-2405RK-05 Combustible Ga s Tr a nsm itter • 9

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

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 cali bration.

• 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 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 calibration gas
flow rate is too low.

• The calibration gas is
not an appr opriate
concentration.

• The transmitter is
malfunctioning.

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

2. Calibrate the transm itter.

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. 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.

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

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

Replacing Components of the Combustible Gas Transmitter

This section includes procedures to replace the combustible gas detector and amplifier.

Replacing the Combustible Gas Detector

1. Turn off the controller.

2. Turn off or unplug power to the controller.

3. Remove the junction box co ver.

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.

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.

10 • 65-2405RK-05 Combustible Gas Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

8. Connect the detector leads to the detector terminal strip as shown in Table 3 below
and Figure 3 on page 6 of th is manual.

Table 3:Reconnecting the Combustible Gas

Detector to the Amplifier

Detector Lead Detector Terminal Strip

Red LEL “R”

White LEL “W”

Green LEL “G”

Black LEL “B”

9. Reinstall the detector terminal strip into its socket.

10. Reinstall the junction box cover.

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

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

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

the next step.

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

Replacing the Amplifier

1. Turn off the controller.

2. Turn off or unplug power to the controller.

3. Remove the junction box co ver.

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. Place the new amplifier in the same position as the old amplifier. A foam gasket that
orients the amplifier and keeps it from rotating is installed on the bottom of the
amplifier. Make sure th e amplifier is seated flat in the junction box.

8. Install the amplifier into the junction box with the screw, lock washer, and flat washer
you removed in Step 5 ab ove.

9. Install the detector and controller terminal strips into their sockets on the new
amplifier as shown in Figure 3 on page 6 of this manual. If controller leads or detector
leads were removed during this procedure, refer to Table 4 and Table 5 below.

65-2405RK-05 Combustible Gas Transmitter • 11

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

Table 4:Reconnecting the Amplifier

to the Controller

Amplifier Controller

Terminal Strip

PWR/SIG “-” - (DC -)
PWR/SIG “S” S (4 - 20 mA In)
PWR/SIG “+” + 24V

Table 5:Reconnecting the ppm

Detector to the Amplifier

Amplifier Detector

T erminal Strip

DETECTOR “R” RED
DETECTOR “W” WHT
DETECTOR “G” GREEN

DETECTOR “B” BLK

Controller

Transm itte r Terminal

Strip (typical)

Detector Lead

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.

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

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

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

13. Calibrate the transmitter as described 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 3 to 6 months is adequate for most combustible gas
transmitter 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 combustible 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 combustible gas 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 months will be necessary.

12 • 65-2405RK-05 Combustible Gas Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

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 libra t ion

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

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

WARNING: Do not remove the junction box cover while the circuits are energized

unless the area is determined to be non-hazardous. Keep the junction box
cover tightly closed during operation.

1. Unscrew and remove the junction box cover.

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

3. Plug the voltmeter leads into the test points on the amplifier. P lug the positive lead
into the red (+) test point; plug the negative lead into the black (-) test point.

4. Use the following formula to determine the correct test points o utput 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

5. Screw the calibration cup on the detector housin g.

Setting the Zero Reading

NOTE: If you can verify that the combustible gas 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. Use the calibration kit sample tubing to connect the regulator to the calibration cup.

3. Turn the regulator’s on/off knob counterclockwise to open the regulator.

65-2405RK-05 Combustible Gas Transmitter • 13

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

4. Allow the gas to flow for one minute 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’s on/off knob clockwise to close the regulator.

6. Unscrew the regulator from the zero air calibration cylinder.

7. Leave the sample tubing connected to the regulator and the calibra tion 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’s on/off knob counterclockwise 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 pot on
the amplifier to adjust the reading to match the correct response reading.

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

5. Unscrew the regulator from the calibration cylinder.

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

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

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

14 • 65-2405RK-05 Combustible Gas Transmitter

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com

Parts List

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)
18-0001RK Reducer, 3/4 in. NPT x 1/2 in. NPT
18-0400RK-01 Junction box with spacers
57-1053RK Amplifier with gasket (spe cify t a rget gas and th at the 61 -0140RK-05 detec tor is

61-0140RK-05 Combustible gas detector, CSA type
65-2405RK-05 Combustible gas transmitt er (inclu des dete ctor and amplifi er; spec ify ta rget gas

71-0180RK 65-2405RK-05 Combustib le Ga s Transmitter Operator’s Manual (this docu-

81-0002RK-01 Steel calibration cylinder, 50% LEL hydrogen in air, 34-liter
81-0007RK-01 Steel calibration cylinder, 15% LEL hexane in air, 34-liter
81-0012RK-01 Steel calibration cylinder, 50% LEL methane in air, 34-liter
81-0076RK-01 Steel calibration cylinder, zero emission air, 34-liter
81-1050RK Regulator, 0.5 liter/minute; with pressure gauge and flow control knob, for 17

81-1117RK Calibration cup
81-F001RK-LV Calibration kit, includes regulator, sample tubing, calibration cup, and 34 liter

81-F002RK-LV Calibration kit, includes regulator, sample tubing, calibration cup, and 34 liter

81-F004RK-LV Calibration kit, includes regulator, sample tubing, calibration cup, and 34 liter

being used w hen ordering)

when ordering)

ment)

liter and 34 liter steel calibration cylinders

15 %LEL hexane in air steel calibration cylinder

50 %LEL methane in air steel calibrati on cylin der

50 %LEL hydrogen in air steel calibration cylinder

65-2405RK-05 Combustible Gas Transmitter • 15

Find Quality Products Online at: [e-mail]

www.GlobalTestSupply.com