RKI Instruments 65-2451RK-04 User Manual

Part Number: 71-0298RK
Revision: P1

65-2451RK-04

Hydrogen Transmitter

Operator’s Manual

Released: 11/8/13

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 3 and 6 months, but can be
required more often or less often based on your usage.

65-2451RK-04 Hydrogen 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 RK I 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 i ndemnification for a n y a c c ident or damage cause d by the operation of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.

65-2451RK-04 Hydrogen Transmitter

Table of Contents

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

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

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

Hydrogen Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Calibration Cup/Splash Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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

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

Mounting the Hydrogen Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wiring the Detector to the Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Wiring the Amplifier to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replacing Components of the Hydrogen Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Determining Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

65-2451RK-04 Hydrogen Transmitter

Overview

This manual describe s the 65-2451RK- 04 hydro gen transmit ter . This manual al so describes
how to install, start 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 th e hydrogen transmitter.

Specifications

Table 1 lists specifications for the hydrogen transmitter.

Table 1:Specifications

Description Specification

Target Gas Hydrogen (H

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
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)

)

2

WARNING: When using the 65-2451RK-04, you must follow the instructions and

warnings in this manual to assure proper and safe opera tion of the
65-2451RK-04 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 65-2451RK-04 as described in this
manual.

65-2451RK-04 Hydrogen Transmitter • 1

Description

Factory Adjust P ot

Span P ot

This section describes the components of the hydrogen transmitter. The transmitter is a 4 ­20 mA type detector head. It consists of the hydrogen detector, calibration cup/splash
guard, amplifier, the amplifier junction box, and the detector junction box. The two
junction box configuration is in tended 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.

Controller Term inal
Strip

Zero Pot

Factory Adjust

Jump er Pin s,

Factory Use

Only

+ Test Point

- TestPoint
Detector Terminal

Pot

Strip

Am plif ier

SPAN

ZERO

Sensor

Current

m A

S

PWR / SIGLEL

57-1053RK

S2 001

GWRB

Terminal Strip

Am plif ier J- Box

Detector J-Box

Hydrogen Detector

Calibration Cup/Splash Guard

Figure 1: Hydrogen Transmitter Component Location

2 • 65-2451RK-04 Hydrogen Transmitter

Hydrogen Detector

The hydrogen detector is a catalytic type detector that produces an electrical output that
corresponds to the detection range. It is packaged in a 1/2 inch NPT nipple with a
sintered metal flame arrestor on one end allowing ambient air to diffuse into the detector.
The flame arrestor also contains any sparks which may occur within the detector. The
detector has a built in molecular sieve that only allows hydrogen to diffuse into the
detector. The 1/2 inch NPT mounting threads at the top of the detector allow you to
mount it into the bottom conduit hub of the junction box. A rainshield screws onto the
bottom of the detector (flame arrestor end). The rainshield helps protect the detector from
rain and debris in the monitoring environment. Four color-coded leads extend from the
top of the detector. The leads allow you to connect the detector to the amplifier.

Calibration Cup/Splash Guard

A calibration cup/splash guard is installed on the rainshield of the hydrogen detector. A
fitting at the bottom of the calibration cup/splash guard allows a length of tubing to be
connected for calibr ation 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 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 example
from a hydrogen calibration to a methane 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 hydrogen 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 hydrogen 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

65-2451RK-04 Hydrogen Transmitter • 3