RKI Instruments Pioneer 4W User Manual

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Pioneer Gas Monitor

Operator’s Manual

Part Number: 71-0027RK Edition: Second Released: June 2001

RKI Instruments, Inc. • 33248 Central Ave, Union City, CA 94587 • (510) 441-5656

Warranty

RKI Instruments, Inc., warranties gas alarm equipment manufactured by RKI and sold by RKI to be free from defects in materials and workmanship for a period of one year from date of shipment from RKI Instruments, Inc. Any parts found defective within that period will be repaired or replaced, at our option, fr ee of char ge. This warranty does not apply to items that are subject to deterioration or consumption in normal service, and which must be cleaned, repaired, or replaced routinely. Those items include, but are not limited to:

absorbent cartridges sensors pump diaphragms and valves ﬁlter elements lamp bulbs and fuses batteries

This warranty is voided by mechanical damage, misuse, alteration, rough handling, or repairs not in accordance with the operator’s manual. This warranty indicates the full extent of our liability. We ar e not responsible for r emoval or r eplacement costs, local repair costs, transportation costs, or contingent expenses incurred without our prior approval.

HIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTIES AND REPRESENTATIONS

EXPRESSED OR IMPLIED

NSTRUMENTS

MERCHANTABILITY

NSTRUMENTS DAMAGE PRODUCTS

, I

ANY

FUNCTION

INCLUDING

KIND

AND

ALL

FITNESS

CONNECTED

LIABLE

OPERATE

FOR

OTHER BUT

INDIRECT

WITH

NOT

OBLIGATIONS

LIMITED

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INCIDENTAL

THE

USE

PROPERLY

THE

PURPOSE

ITS

LIABILITIES

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. I

CONSEQUENTIAL

PRODUCTS

EVENT

THE

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SHALL

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RKI

LOSS

ITS

RKI

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

We do not assume indemniﬁcation for any accident or damage caused by the operation of this gas monitor. Our warranty is limited to replacement of parts or our complete goods.

ii • Warranty Pioneer Gas Monitor Operator’s Manual

Table of Contents

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

About the Pioneer Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Speciﬁcations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 2: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

External Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Internal Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Chapter 3: Installation and Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mounting the Pioneer Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring the Pioneer Gas Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Starting Up the Pioneer Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 4: Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Alarm Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Instrument Setup Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Display Setpoints and Readings Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chapter 5: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Appendix A: Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Appendix B: Gas Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Gas Detection Options for the Pioneer Gas Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Pioneer Gas Monitor Operator’s Manual Table of Contents • iii

iv Pioneer Gas Monitor Operator’s Manual

Chapter 1: Introduction

Overview

This chapter brieﬂy describes the Pioneer Gas Monitor. This chapter also describes the

Pioneer Gas Monitor Operator’s Manual

lists the speciﬁcations for the Pioneer.

About the Pioneer Gas Monitor

The Pioneer is a ﬁxed-mounted, continuous-monitoring instrument. This multiple channel gas monitor is capable of detecting gas at up to four locations. The display screen simultaneously displays the gas readings of all active channels.

The Pioneer includes audible and visual alarms that warn you of hazardous gas conditions. The alarm circuit includes three levels of alarms: alarm 1, alarm 2, and alarm 3. The fail circuit alerts you to failures in the detector(s) or monitor.

(this document). Table 1-1 at the end of this chapter

Four instrument programs allow you to display and change instrument, channel, and calibration settings.

About this Manual

The

Pioneer Gas Monitor Operator’s Manual

•

Chapters 1 through 5

start up, operate, and maintain the Pioneer.

•

Appendix A

accessories offered for the Pioneer.

•

Appendix B

with your Pioneer . If you add an additional gas detection channel at a later date, make sure you add the applicable manual insert to Appendix B to keep your manual up to date.

The

Pioneer Gas Monitor Operator’s Manual

cautions, and warnings.

NOTE:

CAUTION:

Describes additional or critical information.

is organized as follows:

describe components of the Pioneer and procedures to install,

lists the part numbers and descriptions for replacement parts and

includes manual inserts for the gas detection channels originally shipped

uses the following conventions for notes,

Describes potential damage to equipment.

WARNING: Describes potential danger that can result in injury or death.

Pioneer Gas Monitor Operator’s Manual Introduction • 1

Speciﬁcations

Table 1-1 lists speciﬁcations for the Pioneer. See the applicable detection insert in Appendix B, Gas Detectors, for speciﬁcations that apply to the detectors supplied with the Pioneer.

Input Power • 100 to 125 VAC, 50/60 Hz

Construction (housing) Fiberglass/polyester with lexan window (NEMA 4X) Dimensions 12.0 in. H x 10.0 in. W x 6.0 in. D Weight 8 lbs. (without analyzer cards or AC line cord) User Controls • Reset switch

Table 1-1: Speciﬁcations

• 200 to 250 VAC, 50/60 Hz (optional)

• 11 to 22 VDC or 23 to 60 VDC

• Program buttons (ESCAPE, UP/YES, DOWN/NO, and ENTER)

Relays Rated for 8 amps at 250 VAC resistive, Form C Standard Accessory Operator’s manual (this document)

2 • Introduction Pioneer Gas Monitor Operator’s Manual

Chapter 2: Description

Overview

This chapter describes external and internal components of the Pioneer Gas Monitor.

External Description

This section describes the housing and all external components of the Pioneer. For the purposes of this description, the housing door is considered the front of the monitor.

Housing

The Pioneer’s ﬁberglass housing is weather- and corrosion-resistant. It is suitable for installation where general purpose equipment is in use. The housing door is hinged on the left side and is secured by two latches on the right side. The display screen and status lights are visible through a window in the housing door. Four mounting feet are attached to the back of the housing (one at each corner). The mounting feet allow you to install the housing to a vertical surface. Four conduit hubs on the bottom of the housing are for external wiring connections.

CAUTION:

To avoid electrical interference, do not route detector and power wiring through the same conduit hub. Always install a 3/4 in. NPT conduit plug in any unused hub. See Appendix A. Parts List, for ordering information.

Buzzer

The buzzer is on the bottom of the housing. It is behind the reset switch. The buzzer sounds audible alarms to warn you of gas alarms and instrument failures.

Reset Switch

The reset switch is on the bottom of the housing. It is in front of the buzzer. The reset switch serves three functions:

• You can reset the alarm circuits for “latched” alarms after an alarm 1, alarm 2, or alarm 3 condition passes.

• If the alarm silence setting is ON in the Instrument Setup program, you can silence the buzzer during an alarm 1, alarm 2, or alarm 3 condition. You cannot silence failure alarms.

You can adjust the alarm silence setting in the Instrument Setup program (see Chapter 4, Operation).

• You can run the Display Setpoints and Readings program (see Chapter 4, Operation).

Pioneer Gas Monitor Operator’s Manual Description • 3

Internal Description

This section describes the internal components of the Pioneer.

Display screen

Alarm lights

(see Fig. 2-2)

AC fuses

(115V—1 amp top only)

(220V—1/2 amp both)

Power switch

AC terminal strip

External wiring

terminal strips (lower)

External wiring

terminal strips (upper)

Buzzer

(behind switch)

Ground stud

Transformer

(under display

screen board)

PILOT light

FAIL light

Housing

Program buttons

(see Fig. 2-2)

Analyzer card

socket (4)

DC fuse

(3A, 250V)

Expansion terminal strip

Analyzer Card

terminal strips

Relay

Recorder output

Detector

Conduit hubs

(3/4 in. NPT)

Reset switch

Figure 2-1: Pioneer Gas Monitor Component Location

4 • Description Pioneer Gas Monitor Operator’s Manual

Fuses

The Pioneer includes up to two AC fuses and one DC fuse.

AC fuse(s)

Two AC fuse holders are above the power switch (near the upper left corner of the main circuit board). The AC fuse(s) protects the AC line circuitry from short circuit or overload.

For a 115 VAC power source, a 1-amp fuse is installed in the top fuse holder. For a 220 VAC power source, two 1/2-amp fuses are installed in the top and bottom fuse holders.

NOTE:

DC fuse

The DC fuse is to the right of the fourth analyzer card socket (near the lower right corner of the main circuit board). The DC fuse protects the DC line circuitry from short circuit or overload. The DC fuse is rated at 3 amps.

The standard conﬁguration is for 115 VAC operation. 220 VAC operation is an

optional conﬁguration and must be speciﬁed when ordering.

Power Switch

The power switch is directly below the AC fuse. The power switch turns the incoming power source on and off at the Pioneer. When the switch is up, the power switch is on. A round polycarbonate guard is mounted to the switch bushing to protect against accidental contact with live parts on the circuit board near the switch.

Transformer

The transformer is to the right of the AC fuse (under the display screen). The transformer receives the incoming AC voltage and converts it to a nominal DC voltage.

Ground Stud

The ground stud extends from the bottom left corner of the main circuit board. Remove the nut to install a ground wire terminated with a #10 lug, then replace the nut.

CAUTION: Do not use the GND terminal to connect the ground wire. Use the ground stud

described above.

Terminal Strips

The Pioneer includes four terminal strips for external wiring connections. See Chapter 3, Installation and Start Up, for wiring procedures.

NOTE: The analyzer card also includes three terminal strips. They are described at the

end of this chapter.

AC terminal strip

The 3-point AC terminal strip is below and to the right of the power switch. You connect the incoming AC power source to the AC terminal strip. The AC terminal strip is labeled

TB1 on the main circuit board. A polycarbonate terminal cover protects against

accidental contact with the live terminal screws once power to the unit is turned on.

Pioneer Gas Monitor Operator’s Manual Description • 5

External wiring terminal strips

Two external wiring terminal strips are below the AC terminal strip and to the left of the relays. Each 12-point terminal strip includes a lower (terminals 1 through 6) and upper (terminals 7 through 12) row of terminals. The external wiring terminal strips are labeled

TB2 and TB3 on the main circuit board. Table 2-1 lists the function of the external wiring

terminal strips.

Table 2-1: Terminal Assignments for the External Wiring Terminal Strips

Terminal Number Wire to:

TB3

TB2

Expansion terminal strip

The 3-point expansion terminal strip is below and between the third and fourth analyzer card sockets (near the bottom right corner of the main circuit board). You can network up to four Pioneers together by using the expansion terminal strip. The expansion terminal strip is labeled TB4 on the main circuit board.

1 Not currently used

2, 3 RS-485 connection to a personal computer (PC)

4 Shield

5, 6 RS-232 connection to a PC

7 - 9 External alarm for common alarm 3 relay

10 - 12 External alarm for common alarm 2 relay

1, 2 DC power source (Y ou can use DC power as a primary

or backup power source.) 3, 4 The buzzer (factory-wired) 5, 6 The reset switch (factory-wired)

7 - 9 External alarm for common alarm 1 relay

10 - 12 External alarm for common fail relay

Relays

NOTE: Each analyzer card also includes alarm 3, alarm 2, and alarm 1 relays that are

dedicated to the channel that the analyzer card is plugged into.

Four relays are to the right of the external wiring terminal strips. The relays are singlepole, double-throw (SPDT) and are rated for 8 amps at 250 VAC (resistive). The relays are from top to bottom alarm 3, alarm 2, alarm 1, and fail. The relays are common for all channels. For example, the alarm 1 relay energizes when any active channel goes into an alarm 1 condition.

NOTE: You can select normally energized or normally de-energized relays in the

Instrument Setup program. This section describes the default setting: normally de-energized. The fail relay is factory-set as normally energized and is not user-selectable.

6 • Description Pioneer Gas Monitor Operator’s Manual

Display Screen

NOTE: The display screen, status lights, and program buttons are mounted to a small

circuit board. The circuit boar d is mounted to the main cir cuit board by standof fs.

The display screen is mounted to a circuit board that is installed in front of the main circuit board. The display screen simultaneously displays the target gas, measuring unit, and current gas reading of all active channels.

The display screen also displays messages, settings, and other data when you are operating the instrument programs (see Chapter 4, Operation).

FAIL light

PILOT light

Display screen

ALARM 3 light

ALARM 2 light

ALARM 1 light

Data logging chip (optional)

ESCAPE button

UP/YES button

DOWN/NO button

ENTER button

Figure 2-2: Display Screen Component Location

Status Lights

The Pioneer includes six status lights that indicate the current status of the monitor.

POWER light

The POWER light is on the main circuit board near the top edge. The green POWER light is on when the Pioneer has live power connected and the power switch is in the ON position.

PILOT light

The PILOT light is above the display screen and to the left of the FAIL light. The green PILOT light is on when the monitor is receiving incoming power. The PILOT light ﬂashes when the alarms are disabled. The alarms are disabled during instrument warm up and when you enter one of the Pioneer’s various programs.

FAIL light

The FAIL light is above the display screen and to the right of the PILOT light. The FAIL light turns on when the Pioneer is experiencing a fail condition. A fail condition can be caused by a failure within the monitor or detector(s) wired to the monitor. See Chapter 5, Maintenance, or the troubleshooting section in the applicable detection insert to respond to a fail condition.

Pioneer Gas Monitor Operator’s Manual Description • 7

ALARM 3 light

The ALARM 3 light is to the left of the display screen. The ALARM 3 light turns on when the Pioneer is experiencing an alarm 3 condition (see Chapter 4, Operation).

ALARM 2 light

The ALARM 2 light is to the left of the display screen and below the ALARM 3 light. The ALARM 2 light is on when the Pioneer is experiencing an alarm 2 or alarm 3 condition.

ALARM 1 light

The ALARM 1 light is to the left of the display screen and below the ALARM 2 light. The ALARM 1 light turns on when the Pioneer is experiencing an alarm 1, alarm 2, or alarm 3 condition.

Program Buttons

The Pioneer includes four program button that allow you to enter the instrument programs, navigate through the programs, update instrument and channel settings, and save changes to the program settings.

ESCAPE button

The ESCAPE button is above and to the right of the display screen. Use the ESCAPE button to:

• move backward through the instrument programs

• cancel changes you make in the instrument programs

• enter the Instrument Setup program (when pressed with the ENTER button)

UP/YES button

The UP/YES button is to the right of the display screen and below the ESCAPE button. Use the UP/YES button to:

• change settings within the instrument programs

• enter the Calibration program (when pressed with the ENTER button)

DOWN/NO button

The DOWN/NO button is to the right of the display screen and below the UP/YES button. Use the DOWN/NO button to:

• change settings within the instrument programs

• enter the Channel Setup program (when pressed with the ENTER button)

ENTER button

The ENTER button is to the right of the display screen and below the DOWN/NO button. Use the ENTER button to:

• move forward through the instrument programs

• save changes you make in the instrument programs

• enter the Instrument Setup program (when pressed with the ESCAPE button)

• enter the Calibrate program (when pressed with the UP/YES button)

• enter the Channel Setup program (when pressed with the DOWN/NO button)

8 • Description Pioneer Gas Monitor Operator’s Manual

Analyzer Card

The analyzer card plugs into one of four u-shaped sockets near the bottom right corner of the main circuit board. Each channel of detection includes an analyzer card. The analyzer card includes the detector terminal strip, analog output terminal strip, external alarms terminal strip, pilot light, and three relays.

The terminals unplug from the terminal strips to give better access to the terminals when you make wiring connections.

Detector terminal strip

The 7-point detector terminal strip (terminals 1 through 7) is the terminal strip closest to the bottom of the analyzer card. You connect wiring from the detector to the detector terminal strip.

NOTE: See the applicable detection insert in Appendix B, Gas Detectors, to wire the

detector to the analyzer card.

Analog Output terminal strip

The 2-point analog output terminal strip (terminals 8 and 9) is directly above the detector terminal strip. You connect wiring from a recording device (if applicable) to the analog output terminal strip.

The output at the analog output terminal strip is 4 to 20 mA or 0 to 1 V. The output is selectable by jumpers on the analyzer card. The standard (default) output is 4 to 20 mA.

External alarms terminal strip

NOTE: The Pioneer also includes two common external alarm terminal strips. These

common terminal strips activate external alarms for all active channels.

The 9-point external alarm terminal strip is above the analog output terminal strip. You connect wiring from external alarms (if applicable) to the external alarm terminal strip. This terminal strip has common (C), normally closed (NC) and normally open (NO) terminals for alarm 1, alarm 2, and alarm 3 connections.

Pilot light

The pilot light is between the external alarms terminal strip and analog output terminal strip. The pilot light ﬂashes when the analyzer card is receiving power and operating normally. The pilot light does not ﬂash or is off when a failure occurs.

Pioneer Gas Monitor Operator’s Manual Description • 9

Relays

NOTE: The Pioneer also includes four common relays (to the left of the analyzer card

sockets). The common relays activate for all active channels.

Three relays are behind the external alarm terminal strip. The relays are single-pole, double-throw (SPDT) and are rated for 8 amps at 250 VAC (resistive). The relays are from top to bottom alarm 1, alarm 2, and alarm 3. The relays are dedicated to the channel that the analyzer card is plugged into only. For example, the alarm 1 relay energizes only when the channel that the card is plugged into goes into an alarm 1 condition.

NOTE: You can select normally energized or normally de-energized relays in the

Instrument Setup program. This section describes the default setting: normally de-energized.

10 • Description Pioneer Gas Monitor Operator’s Manual

Chapter 3: Installation and Start Up

Overview

This chapter describes procedures to mount the Pioneer Gas Monitor, make wiring connections to the monitor, and start up the monitor.

WARNING: Perform all installation and start-up procedures in a “fresh air”

environment (known to be free of combustible gas, toxic gas, and of normal oxygen content). The Pioneer is not in operation as a gas monitoring system until the start-up procedure is complete.

Pioneer Gas Monitor Operator’s Manual Installation and Start Up • 11

Mounting the Pioneer Gas Monitor

Perform the following procedure to install the instrument housing at the mounting site.

1. Select the mounting site. When you select the mounting site consider the following factors:

• Is an AC or DC power source available?

• Is there enough room to open the housing door and make wiring connections

through the conduit hubs at the bottom of the housing?

• Are the display screen and status lights visible?

2. If necessary, close and latch the housing door.

3. Position the monitor on a vertical surface at eye level (4 1/2 to 5 feet from the ﬂoor).

4. Insert 1/4 in. or 5/16 in. screws through the slots in the mounting feet at each corner of the housing to secure the housing to the mounting surface (see Figure 3-1).

10.5 in.

8.0 in.

13.4 in.

12.5 in.

12.9 in.

3/4 in. conduit hub

(total of 4 hubs)

Note: The housing is 6.25 in. deep.

Figure 3-1: Pioneer Gas Monitor Outline and Mounting Dimensions

12 • Installation and Start Up Pioneer Gas Monitor Operator’s Manual

INDIVIDUAL ALARM 1

ALARM 2 ALARM 1

INDIVIDUAL ALARM 2

ALARM 3

INDIVIDUAL ALARM 1

ANALOG OUTPUT

4 to 20 mA

RECORDER

(SEE MANUAL FOR OTHER OUTPUTS)

FOR EACH SET OF ALARM RELAYS CONTACTS.

CONTACT RATING OF 8 AMPS RESISTIVE AT 24VDC

ALARM 3

COMMON

4 to 20 mA

ALARM 2

COMMON

GROUND

24V

(3-wire type)

Sensor/Transmitter

(2-wire type)

Sensor/Transmitter

ALARM 1

COMMON

4-20

RED

WHITE

COMMON

FAIL ALARM

GREEN

BLACK

(typical wiring)

AND HOUSING

OXYGEN SENSOR

green

white

NOTE 3: See Appendix B

for other detection types.

(typical wiring)

AND HOUSING

COMBUSTIBLE SENSOR

green

ALARM DEVICE POWER

of main circuit board.

NOTE 1: Connect ground wire to

ground stud on lower left corner

GROUND

AC POWER

HOT

NEUTRAL

connection)

(see manual

for 230VAC

115V, 60 HZ.

ALARM 3

COMMON

18293104115126

SHIELD

RS 485

(see manual)

NO CONNECTION

ALARM 2

COMMON

RS 232

(see manual)

NO 7

1 +

24 VDC

STANDBY

DC POWER

ALARM 1

COMMON

NC 9

INTERNAL

FAIL

NO 10

BUZZER

COMMON

NC 12

321

RESET

red

SDA

CLK GND

RESET

SWITCH

black

(see manual)

EXPANSION

(internal)

Figure 3-2: Pioneer Gas Monitor External Wiring Diagram

NOTE 2: The internal buzzer and

reset switch are factory-wired.

Pioneer Gas Monitor Operator’s Manual Installation and Start Up • 13

Wiring the Pioneer Gas Monitor

This section describes procedures to connect the AC power source, DC power source, external alarm(s), recorder, and detector(s). See Figure 3-2 for a general wiring diagram of all external wiring to the Pioneer.

conduit plugs in all unused conduit hubs. See Appendix A. Parts List, for ordering information.

W ARNING: Make all connections to the Pioneer befor e you plug in or turn on the AC or

DC power source. Before you make any wiring adjustments, always verify that all power sources are not live.

Connecting the AC Power Source

After completing all wiring connections, install 3/4 in. NPT

NOTE:

If you are using DC power as the primary power source, go to the next section, “Connecting the DC Power Source” on page 15.

Perform the following procedure to connect the AC power source to the Pioneer.

WARNING: Verify that the power source is unplugged or turned off at the power source

end before you continue with this procedure.

1. Open the housing door , and locate the AC terminal strip (TB1). See Figure 2-1, Pioneer Gas Monitor Component Location, to assist you in locating the AC terminal strip.

2. Remove the AC terminal cover by removing the two screws that retain it.

3. Guide the AC power cord through the leftmost conduit hub on the bottom of the Pioneer housing.

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

wiring may disrupt the transmission of the detector signal to the monitor.

4. Connect the AC line to the AC terminal strip as shown in Figure 3-3. (Connect the ground wire to the ground stud on the lower left corner of the main circuit board.)

5. Replace the AC terminal cover.

(factory-wired) Ground

Neutral

Hot

1 2

AC Power Source

AC Terminal Strip

Figure 3-3: AC Power Wiring

14 • Installation and Start Up Pioneer Gas Monitor Operator’s Manual

Connecting the DC Power Source

WARNING: Verify that the power source is unplugged or turned off at the power source

end before you continue with this procedure.

Perform the following procedure to connect the DC power source to the Pioneer.

NOTE: A jumper block located at the middle upper edge of the main circuit board

allows you to conﬁgure the Pioneer to operate from either 12 VDC or 24 VDC.

To select 12 VDC operation (input range of 11 to 22 VDC), install the jumper

block over the right two pins. To select 24 VDC operation (input range of 23 to 60 VDC), install the jumper block over the left two pins. The factory default conﬁguration is for 24 VDC operation.

1. Open the housing door, and locate the bottom external wiring terminal strip (TB2). See Figure 2-1, Pioneer Gas Monitor Component Location, to assist you in locating the bottom external wiring terminal strip.

2. Guide a DC power cord through one of the conduit hubs on the bottom of the Pioneer housing.

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

wiring may disrupt the transmission of the detector signal to the monitor.

3. Connect the DC line to the lower row of terminals on the external wiring terminal strip as shown in Figure 3-4.

1 2

DC Power Source

Figure 3-4: DC Power Wiring

External Wiring Terminal Strip (TB2)

Connecting External Alarms

Perform the following procedure to connect external alarms to the Pioneer.

NOTE: The analyzer card includes external alarm connections that are dedicated to the

applicable channel only. See Appendix B, Gas Detectors, to wire external alarms to the analyzer card.

1. Open the housing door, and locate the external wiring terminal strips (TB2 and TB3). See Figure 2-1, Pioneer Gas Monitor Component Location, to assist you in locating the external wiring terminal strips.

2. Guide the wiring of the external alarm through one of the conduit hubs on the bottom of the Pioneer housing.

Pioneer Gas Monitor Operator’s Manual Installation and Start Up • 15

CAUTION: If the external alarm device is powered by AC current, do not route the external

alarm wiring and detector wiring through the same conduit hub. The external alarm wiring may disrupt the transmission of the detector signal to the Pioneer.

3. Connect the leads from the external alarm to the terminals on the appropriate external wiring terminal strip as shown in Figure 3-5. See Table 2-1, Terminal Assignments for the External Wiring Terminal Strips, to determine the applicable external alarm terminals.

External

Power Source

+ (H)

COM

External Wiring Terminal Strip (TB2, TB3)

— (N)

+ (H)

— (N)

External

Alarm Device

Figure 3-5: External Alarm Wiring

4. Repeat steps 2 and 3 for additional external alarms.

Connecting Recorders

Perform the following procedure to connect a recor ding device to the Pioneer. The output at the analyzer card’s analog output terminal strip is a 4 to 20 mA proportional to the detection range of the applicable detector. Unless speciﬁed, the analyzer card is set up at the factory for 4 to 20 mA output.

1. Open the housing door, and locate the analog output terminal strip on the applicable analyzer card. (The analog output terminal strip is the 2-point terminal strip between the detector terminal strip and the external alarm terminal strip.)

0 to 1 V signal that is

2. Guide the wiring from the recording device through one of the conduit hubs on the bottom of the Pioneer housing.

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

wiring may disrupt the transmission of the detector signal to the monitor.

3. Connect the leads from the recording device to the analog output terminal strip as shown in Figure 3-6.

Recording

Device

—

(Rec Out +)

(Rec Out -)

Analog Output Terminal Strip

(on analyzer card)

Figure 3-6: Recorder Output Wiring

16 • Installation and Start Up Pioneer Gas Monitor Operator’s Manual

Connecting RKI Detectors

See the manual insert(s) in Appendix B, Gas Detectors, to wire the detector(s) supplied by RKI Instruments, Inc., to the Pioneer.

Connecting User-Supplied 4 to 20 mA Transmitters

NOTE: : See the manual insert, “Generic 4 to 20 mA Transmitter,” in Appendix B,

Gas Detectors, for more detailed information related to the use of user-supplied 4 to 20 mA transmitters with the Pioneer.

Perform the following procedure to connect a 4 to 20 mA transmitter (that you supply) to the Pioneer.

1. Open the housing door, and locate the detector terminal strip on the applicable analyzer card. (The detector terminal strip is the 7-point terminal strip that is below the analog output terminal strip.)

2. Route the cable leading from the transmitter through one of the conduit hubs on the bottom of the Pioneer housing.

Transmitter

(+)

(-)

(FB)

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

power wiring may disrupt the transmission of the transmitter’s signal to the Pioneer.

3. Connect the wires to the detector terminal strip of the applicable analyzer card as shown in Figure 3-7. The detector is the 7-point terminal strip (terminals 1 through 7) on the card.

3-Wire Connection

7 Gnd

6 24 V

5 4-20 4 RED 3 WHT 2 GRN 1 BLK

Detector Terminal Strip

(+)

(-/FB)

Transmitter

2-Wire Connection

Detector Terminal Strip

7 Gnd 6 24 V 5 4-20 4 RED 3 WHT 2 GRN 1 BLK

Figure 3-7: Generic 4 to 20 mA Transmitter Output Wiring

Pioneer Gas Monitor Operator’s Manual Installation and Start Up • 17

Starting Up the Pioneer Gas Monitor

Perform the following procedure to place the Pioneer into normal operation.

1. Complete the mounting and wiring procedures described earlier in this chapter.

2. Complete all installation procedures described in Appendix B, Gas Detectors.

3. Verify that all wiring connections are correct and secure and the Pioneer’s power switch is in the OFF position.

4. Plug in or turn on the incoming power source (AC or DC) at the power source end.

5. Place the Pioneer’s power switch in the ON position.

NOTE: To prevent unwanted alarms during warm up, the alarm circuits are not active

for 20 seconds to 2 minutes (depending on warm up) from the time you turn the power switch on.

6. Verify the following:

• The PILOT light above the display screen is on.

• The POWER light on the main circuit board is on.

• The pilot light on each analyzer card is ﬂashing.

If the pilot lights are not on or ﬂashing, see the troubleshooting guides in Chapter 5, Maintenance, and Appendix B, Gas Detectors.

7. Perform the start-up procedure for each detector as described in Appendix B, Gas Detectors.

18 • Installation and Start Up Pioneer Gas Monitor Operator’s Manual

Chapter 4: Operation

Overview

This chapter describes the Pioneer Gas Monitor in normal operation. This chapter also describes the Pioneer in alarm 1, alarm 2, alarm 3, and fail conditions and suggests response to these conditions. The Instrument Setup program and Display Setpoints and Readings program are described at the end of this chapter.

Normal Operation

Normal operation is deﬁned as follows:

• the start-up procedure is complete.

• the Pioneer is not indicating an alarm 1, alarm 2, alarm 3, or fail condition.

• the Pioneer is not running the Instrument Setup, Channel Setup, Calibrate, or Display Setpoints and Readings program.

During normal operation, the Pioneer simultaneously displays the target gas, unit of measure, and current gas reading for all active channels. The Pioneer displays the readings horizontally for each channel. If all four channels are installed, channel 1 is the top reading, and channel 4 is the bottom reading.

The PILOT light near the display screen, the POWER light on the main circuit board, and the pilot light on each analyzer card are on during normal condition indicating that the monitor and analyzer cards are receiving incoming power. The output at terminals 8 and 9 of the analyzer card’s output terminal strip is 4 to 20 mA the detection range of the detector that is wired to the analyzer card. (The standard output at terminals 8 and 9 is 4 to 20 mA.)

Alarm Indications

This section describes the Pioneer in alarm 1, alarm 2, alarm 3, and fail conditions and suggests response to these conditions. Table 4-1 lists the alarm indications for each condition.

H2 CH3 C

20.

0 9 0 0

VOL

PP PPM

COMB

OXY

0 to 1 V and is proportional to

NOTE:

Pioneer Gas Monitor Operator’s Manual Operation • 19

The Pioneer includes alarm on and alarm off delay settings. The alarm indications described in this section operate according to the default delay settings. See the Channel Setup program section in the applicable detection insert (Appendix B, Gas Detectors) to display or change the alarm on and alarm off delay settings.

Table 4-1: Visual and Audible Alarm Indications

Condition Cause Visual Indication

Alarm 1 Increasing (decreasing for O2) gas reading

at or above the alarm 1 setpoint

Alarm 2 Increasing (decreasing for O2) gas reading

at or above the alarm 2 setpoint

• ALARM 1 light is on

• Gas reading ﬂashes

• ALARM 1 and ALARM 2 lights are on

• Gas reading ﬂashes

Alarm 3 Increasing gas reading at or above the

alarm 3 setpoint

• ALARM 1, ALARM 2, and ALARM 3 lights are on*

• Gas reading ﬂashes

Fail • Disconnected or misconnected

• FAIL light is on Steady tone

detector wiring

• Disconnected or misconnected analyzer card

• Display reading below fail setpoint

• Defective components

* The ALARM 1 and ALARM 2 lights are not on for oxygen channels.

Audible

Indication

Pulsing tone

Faster pulsing tone than Alarm 1

Faster pulsing tone than Alarm 2

NOTE:

You can select normally energized or normally de-energized relays in the Channel Setup program. The following sections describe the default setting for the relays: normally de-energized. The fail relay is factory-set for normally energized and is not user-selectable.

Alarm 1 Condition

This section describes the audible and visual indications for an alarm 1 condition and suggests response to an alarm 1 condition.

Alarm 1 condition indications

When the gas reading of an active channel reaches the alarm 1 setpoint, the Pioneer senses an alarm 1 condition. The Pioneer alerts you to an alarm 1 condition as follows:

• the ALARM 1 light turns on

• the gas reading in alarm 1 condition ﬂashes

• the buzzer sounds a pulsing tone

• the common alarm 1 relay energizes

• the alarm 1 relay on the applicable analyzer card energizes

Responding to an alarm 1 condition

This section suggests response to an alarm 1 condition.

1. Follow your established procedure for a low level combustible or toxic gas condition or a decreasing oxygen content condition.

20 • Operation Pioneer Gas Monitor Operator’s Manual

2. After the gas reading falls below the alarm 1 setpoint, press the reset switch to reset the alarm 1 circuit. Resetting the alarm 1 circuit silences the buzzer, turns off the ALARM 1 light, and de-energizes the common and analyzer card alarm 1 relays.

NOTE: To silence the buzzer while in an alarm 1 condition, press the reset switch.

You cannot de-energize the alarm 1 relays until the gas reading falls below (above for oxygen) the alarm 1 setpoint.

Alarm 2 Condition

This section describes the audible and visual indications for an alarm 2 condition and suggests response to an alarm 2 condition.

Alarm 2 condition indications

When the gas reading of an active channel reaches the alarm 2 setpoint, the Pioneer senses an alarm 2 condition. The Pioneer alerts you to an alarm 2 condition as follows:

• the ALARM 2 light turns on

• the gas reading in alarm 2 condition continues to ﬂash

• the buzzer sounds a faster pulsing tone than an alarm 1 condition

• the common alarm 2 relay energizes

• the alarm 2 relay on the applicable analyzer card energizes

Responding to an alarm 2 condition

This section suggests response to an alarm 2 condition.

1. Follow your established procedure for a mid level combustible or toxic gas condition or a severe decreasing oxygen content condition.

2. After the gas reading falls below the alarm 2 setpoint, press the reset switch to reset the alarm circuit. Resetting the alarm circuit turns off the ALARM 2 light, and de-energizes the common and analyzer card alarm 2 relays.

NOTE: To silence the buzzer while in an alarm 2 condition, press the reset switch.

You cannot de-energize the alarm 2 relays until the gas reading falls below (above for oxygen) the alarm 2 setpoint.

Alarm 3 Condition

This section describes the audible and visual indications for an alarm 3 condition and suggests response to an alarm 3 condition.

Alarm 3 condition indications

When the gas reading of an active channel reaches the alarm 3 setpoint, the Pioneer senses an alarm 3 condition. The Pioneer alerts you to an alarm 3 condition as follows:

• the ALARM 3 light turns on

• the gas reading in alarm 3 condition continues to ﬂash (the gas reading for O channels begins ﬂashing)

• the buzzer sounds a faster pulsing tone than an alarm 1 or alarm 2 condition

• the common alarm 3 relay energizes

• the alarm 3 relay on the applicable analyzer card energizes

Pioneer Gas Monitor Operator’s Manual Operation • 21

NOTE: The alarm 3 relay does not energize if you elect to use it as the channel’s fail relay

in the Channel Setup program (see the “Channel Setup Program” section of the applicable detection insert in Appendix B, Gas Detectors.)

Responding to an alarm 3 condition

This section suggests response to an alarm 3 condition.

1. Follow your established procedure for a high level combustible or toxic gas condition or an increasing oxygen content condition.

2. After the gas reading falls below the alarm 3 setpoint, press the reset switch to reset the alarm 3 circuit. Resetting the alarm 3 circuit turns off the ALARM 3 light, and de-energizes the common and analyzer card alarm 3 relays.

NOTE: To silence the buzzer while in an alarm 3 condition, press the reset switch.

You cannot de-energize the alarm 3 relays until the gas reading falls below the alarm 3 setpoint.

Fail Condition

This section describes the audible and visual indications for a fail condition and suggests response to a fail condition.

Fail condition indications

The Pioneer senses a fail condition for any of the following:

• the detector wiring is disconnected or incorrectly connected

• the analyzer card is disconnected or incorrectly connected

• the display reading is below the fail setpoint

• the monitor or detector is malfunctioning

When the Pioneer senses a fail condition, it alerts you as follows:

• the FAIL light turns on

• the gas reading in fail condition ﬂashes

• the buzzer sounds a steady tone

• the common fail relay de-energizes

NOTE: If you elected to use the analyzer card’s alarm 3 relay as an individual fail relay

in the Channel Setup program, the relay de-energizes in a fail condition. (See the “Channel Setup Program” section of the applicable detection insert in Appendix B, Gas Detectors.)

Responding to a fail condition

This section suggests response to a fail condition.

1. Verify that the detector wiring is correctly and securely connected.

2. Verify that the analyzer card is securely and correctly installed. (The components of the analyzer card face left when the analyzer card is correctly installed.)

3. See the troubleshooting guide in the applicable detection insert (Appendix B, Gas Detectors).

22 • Operation Pioneer Gas Monitor Operator’s Manual

Instrument Setup Program

This section describes the Instrument Setup program. You can display and change the following instrument settings with the Instrument Setup program.

• Alarm On Delay

• Alarm Off Delay

• Relay Action

• Alarm Logic

• Alarm Silence

• Alarm Hysteresis

• Calibration Time Out

• Instrument ID (RS-232 or RS-485 address)

• Noise Filter

• Maximum Number of Channels (for use when connecting to other Pioneers)

• Zero Suppression

• Instrument Label

Navigating through the Instrument Setup Program

Use the program buttons to the right of the display screen to enter the program, move forward or backward through the pr ogram, change settings within the pr ogram, and save or cancel changes to the program settings. Table 4-2 lists the function of each program button.

Table 4-2: Program Button Functions for the Instrument Setup Program

Button Function

ESCAPE • Moves you backward through the program

• Cancels changes made to the program settings

• Enters the program (with the ENTER button)

UP/YES • Updates the setting that is ﬂashing on the

display screen

DOWN/NO • Updates the setting that is ﬂashing on the

display screen

ENTER • Moves you forward through the program

• Saves changes made to the program settings

• Enters the program (with the ESCAPE button)

Pioneer Gas Monitor Operator’s Manual Operation • 23

Running the Instrument Setup Program

This section describes how to enter the program, display and change program settings, and save or cancel changes to the program settings.

Entering the instrument setup program

1. Open the housing door, and locate the program buttons to the right of the display screen.

2. Press the ENTER and ESCAPE buttons simultaneously three times. The display screen indicates that you are in the Instrument Setup program.

3. Press the ENTER, UP/YES, or DOWN/NO button to continue. The program displays the Alarm ON Delay screen.

Alarm on delay screen

This screen indicates the length of time that the Pioneer delays alarm indications (buzzer and relays) when it senses an alarm 1, alarm 2, or alarm 3 condition. You can choose from a range of 0 Seconds to 60 Minutes. The default setting is

0 Minutes, 1 Seconds .

Alarm

0 1

• To accept the alarm on delay setting and continue the program, press the ENTER button.

The program displays the Alarm OFF Delay screen.

• To update the alarm on delay setting:

1. Use the UP/YES and DOWN/NO buttons to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Alarm OFF Delay screen.

Alarm off delay screen

This screen indicates the length of time that the Pioneer delays turning off alarm indications (buzzer and relays) after an alarm 1, alarm 2, or alarm 3 condition passes. You can choose from a range of 0 Seconds to 60 Minutes. The default setting is 0 Minutes,

0 Seconds .

Alarm 0

NDel Minutes S

econds

Minutes

econds

ay:

De lay :

• To accept the alarm off delay setting and continue the program, press the ENTER button.

The program displays the Relay Action screen.

• To update the alarm off delay setting:

1. Use the UP/YES and DOWN/NO buttons to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Relay Action screen.

24 • Operation Pioneer Gas Monitor Operator’s Manual

Relay action screen

This screen indicates how the relays operate in normal and alarm conditions. If the setting is NORMALLY DE-ENERGIZED , the relays energize in alarm conditions. If the setting is

NORMALLY ENERGIZED , the relays de-energize in alarm conditions. The default

setting is NORMALLY DE-ENERGIZED .

NOTE: The common fail relay and channel fail relay (if assigned) are not af fected by this

setting. Fail relay(s) are factory-set as normally energized and are not adjustable.

RELAYSNORALLY DE-NERGIZED

• To accept the relay action setting and continue the program, press the ENTER button. The program displays the Alarm Logic screen.

• To update the relay action setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Alarm Logic screen.

Alarm logic screen

This screen indicates how an alarm circuit is reset after the applicable alarm condition passes. If the setting is LATCHING , you must press the reset switch after the alarm condition passes to reset the alarm circuit. If the setting is AUTO-RESET , the alarm circuit is automatically reset after the alarm condition passes. The default setting is LATCHING .

ALAR L

HIN

• To accept the alarm logic setting and continue the program, press the ENTER button. The program displays the Alarm Silence screen.

• To update the alarm logic setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Alarm Silence screen.

Pioneer Gas Monitor Operator’s Manual Operation • 25

Alarm silence screen

This screen indicates how the buzzer operates during alarm conditions. If the setting is

, you can use the reset switch to silence the buzzer during alarm conditions. If the setting is OFF , you cannot silence the buzzer until all alarm conditions pass. The default setting is ON .

ARM

AL E E

LCIN

• To accept the alarm silence setting and continue the program, press the ENTER

button. The program displays the Alarm Hysteresis screen.

• To update the alarm silence setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Alarm Hysteresis screen.

Alarm hysteresis screen

This screen indicates when the Pioneer considers an alarm condition passed. The alarm hysteresis feature helps prevent readings that are near an alarm setpoint from frequently going into and out of alarm (relay chattering). For example, if the alarm hysteresis setting is 2.0% of fullscale, fullscale is 10.0 ppm, and the alarm 1 setpoint is 3.0 ppm; then the Pioneer will not consider the alarm 1 condition “passed” until the reading goes below 2.8 ppm. You can choose from a range of 0.0% to 10.0% of fullscale (in 0.1% increments). The default setting is 2.0% .

S ALE

ALAR HMYSTRESI

• To accept the alarm hysteresis setting and continue the program, press the ENTER

button. The program displays the Calibration Time Out screen.

• To update the alarm hysteresis setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Calibration Time Out screen.

26 • Operation Pioneer Gas Monitor Operator’s Manual

Calibration time out screen

The Pioneer’s Calibrate program includes two separate time-out features. The ﬁrst time-out feature is a general 5-minute time-out. The Pioneer automatically returns to the normal screen if you do not move from one Calibrate screen to another within 5 minutes. You cannot adjust this setting, and it affects all Calibrate screens except the Fresh Air and Calibration screens.

The second time-out feature affects the Fresh Air and Calibration screens only. These are the screens you use during calibration to adjust the zero and span readings (either at the transmitter or the Pioneer). The Pioneer automatically returns to the normal screen if you do not move from the Fresh Air or Calibration scr een within the time-out setting speciﬁed in the screen below. You can choose from a range of 10 to 100 minutes (in increments of

10). The default setting is

10 Minutes .

libr

Tim

atio

e-Ou t

nMenu

Minu

tes

• To accept the calibration time out setting and continue the program, press the ENTER

button. The program displays the Instrument ID screen.

• To update the calibration time out setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Instrument ID screen.

Instrument ID screen

This screen indicates the ID number (address) for this Pioneer. The instrument ID is recorded in the datalog when the datalog records instrument readings. This setting is useful if you have more than one Pioneer networked together. You can choose from a range of 1 to 255. The default setting is 1 .

INSTRUMENT ID FOR

RS232&RS4

• To accept the instrument ID setting and continue the program, press the ENTER

button. The program displays the Noise Filter screen.

• To update the instrument ID setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Noise Filter screen.

Pioneer Gas Monitor Operator’s Manual Operation • 27

Noise ﬁlter screen

This screen indicates the length of time that the Pioneer averages data. You can choose from a range of 0.5 to 15.0 seconds (in increments of 0.5). The default setting is 2.5

Seconds .

Filter

Noi

Soe

NOTE: The Pioneer continuously displays gas readings although it averages gas

readings according to the noise ﬁlter setting.

• To accept the noise ﬁlter setting and continue the program, press the ENTER button.

The program displays the Number of Channels screen.

• To update the noise ﬁlter setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Number of Channels screen.

Number of channels screen

This screen indicates the maximum number of channels possible for the Pioneer. The settings are displayed in multiples of 4. For example, if you have three Pioneers networked together, select a setting of 12. You can choose from a range of 4 to16 (in increments of 4). The default setting is 4 .

Chans

Max

#imu

• To accept the number of channels setting and continue the program, press the ENTER

button. The program displays the Zero Suppression screen.

• To update the number of channels setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Zero Suppression screen.

28 • Operation Pioneer Gas Monitor Operator’s Manual

Zero suppression screen

This screen indicates the zero suppression for the Pioneer. The zero suppression feature helps prevent “jumpy” readings near the normal reading. For example, if the zero suppression setting is 2.0% of fullscale and fullscale is 10.0 ppm, then the Pioneer will display a reading of 0.0 ppm for gas readings from -0.2 to 0.2 ppm. You can choose from a range of 0.0% to 5.0% (in 0.1% increments). The default setting is 2.0% .

ZER

OUS

PPR SSI

ALE

• To accept the zero suppression setting and continue the program, press the ENTER

button. The program displays the Instrument Label screen.

• To update the zero suppression setting:

1. Use the UP/YES or DOWN/NO button to display the setting you want.

2. Press the ENTER button to continue the program. The program displays the Instrument Label screen.

Instrument label screen

This screen indicates the identifying label for this Pioneer. The instrument label is recorded in the datalog when the datalog records instrument readings. This setting is useful if you have more than one Pioneer networked together. You can choose a label of up to 15 characters. Characters can be letters, numbers, symbols, or blank spaces. The default setting is RKI INSTRUMENTS .

ent

rum

Label

INSTRUMENT

• To accept the instrument label setting and continue the program, press the ENTER

button until the Instrument Setup Exit screen displays.

• To update the instrument label setting:

1. Use the ENTER button to select the character you want to change. (The character ﬂashes when it is selected.)

2. Press the UP/YES or DOWN/NO button to display the character you want, then press the ENTER button to select the next character.

3. Repeat steps 1 and 2 until the label is correct, then press the ENTER button until the Instrument Setup Exit screen displays.

Pioneer Gas Monitor Operator’s Manual Operation • 29

Instrument setup exit screen

This screen saves or cancels any changes you made in the Instrument Setup program.

APE

= =

reviou

P StoreSet-Up

NTER

• To save changes and exit the program, press the ENTER button. A conﬁrmation message displays, then the normal screen displays. The Pioneer is in

normal operation.

• To cancel changes and exit the program, press the ESCAPE button until the following message displays: “INSTRUMENT SET-UP NOT SAVED. USING PREVIOUS VALUES.”

The normal screen displays. The Pioneer is in normal operation.

Display Setpoints and Readings Program

This section describes the Display Setpoints and Readings program. You can display the following in this program. (You can also allow the Pioneer to perform a self check procedure and reset the minimum and maximum readings in this program.)

• Software versions

• Time Weighted Average (TWA) and Short Term Exposure Limit (STEL) readings (for applicable channels)

• Minimum and maximum readings (for each channel)

• Alarm Sets (for each channel)

Navigating through the Display Setpoints and Readings Program

Use the reset switch to begin the program, display the setpoints and readings, and exit the program.

NOTE: This is a display only program. You cannot change settings or gas readings in the

Display Setpoints and Readings program.

Running the Display Setpoints and Readings Program

This section describes how to display the various setpoints and gas readings that are included in this program. This section also describes how to display the time and date and begin the self check procedure.

NOTE: Once you display one of the screens, the Pioneer automatically returns to the

normal screen in 1 minute if you do not continue or exit the program.

30 • Operation Pioneer Gas Monitor Operator’s Manual

To display software versions:

The Display Setpoints and Readings program displays the version number of the Pioneer’s instrument, display, and channel software programs.

1. Press and hold down the reset switch to enter the program.

2. When the DISPLAY VERSIONS screen appears, release the reset switch.

3. Press and release the reset switch to display the remaining software versions and return to the normal screen.

To display TWA and STEL readings:

The Pioneer continuously computes Time Weighted Average (TWA) and Shot Term Exposure Limit (STEL) readings for all active channels.

NOTE: The Pioneer does not calculate or display TWA and STEL setting for oxygen

channels or combustible gas channels that have a unit of measure setting of

%LEL . However, the Pioneer does calculate and display TWA and STEL settings

for combustible gas channels that have a unit of measure setting of PPM/LEL .

The STEL reading represents a channel’s average gas readings for the past 15 minutes. The TWA reading represents a channel’s average gas readings for the past 8 hours.

1. Press and hold down the reset switch to enter the program.

2. When the DISPLAY TW A/STEL screen appears on the display scr een, release the r eset switch.

The STEL reading displays for the ﬁrst active channel.

3. Press and release the reset switch to display the TWA reading for the ﬁrst active channel.

4. Continue pressing and releasing the reset switch to display the STEL and TWA readings for the remaining channels.

5. Press and release the reset switch to return to the normal screen.

To display minimum and maximum readings:

The Pioneer stores the minimum and maximum reading for all active channels since the last time the minimum and maximum readings were reset.

1. Press and hold down the reset switch to enter the program.

2. When the DISPLAY MIN/MAX screen appears on the display screen, release the reset switch.

The minimum reading displays for the ﬁrst active channel.

3. Press and release the reset switch to display the maximum reading for the ﬁrst active channel.

4. Continue pressing and releasing the reset switch to display the minimum and maximum readings for the remaining channels.

5. Press and release the reset switch to return to the normal screen.

Pioneer Gas Monitor Operator’s Manual Operation • 31

To display alarm sets:

The Display Setpoints and Readings program displays the alarm sets for all active channels. The alarm sets include the alarm logic, alarm silence, alarm setpoint, and alarm type settings.

NOTE: You can change the alarm logic and alarm silence settings in the Instrument

Setup program. You can change the alarm setpoint and alarm type settings in the Channel Setup program.

1. Press and hold down the reset switch to enter the program.

2. When the ALARM SETS screen appears on the display scr een, r elease the r eset switch. The alarm logic setting (LATCHING or AUTO-RESET) displays for all active

channels.

3. Press and release the reset switch to display the alarm silence setting (ON or OFF) for all active channels.

4. Continue pressing and releasing the reset switch to display the setpoint and alarm type for the fail, alarm 1, alarm 2, and alarm 3 alarms of channel 1.

5. Repeat step 4 to display the setpoint and alarm type for the remaining active channels.

6. Press and release the reset switch to return to the normal screen.

To perform the self check:

The Pioneer includes a self check feature that makes sure the analyzer card(s) and microprocessor are operating correctly.

1. Press and hold down the reset switch to enter the program.

2. When the SELF CHECK screen appears on the display screen, release the r eset switch. The Pioneer performs the self check procedure and returns to the normal screen. This

process takes approximately 5 seconds.

To reset Minimum/Maximum readings:

If you reset the minimum and maximum readings, you cannot retrieve the minimum and maximum readings previously stored by the Pioneer.

1. Press and hold down the reset switch to enter the program.

2. When the RESET MIN/MAX screen appears on the display screen, release the reset switch.

3. The message “MIN/MAX RESET DONE” appears on the display screen, then the program returns to the normal screen.

32 • Operation Pioneer Gas Monitor Operator’s Manual

Chapter 5: Maintenance

Overview

This chapter describes corrective maintenance procedures for the Pioneer Gas Monitor. It includes a troubleshooting guide for problems you may encounter with the Pioneer. Procedures to replace components of the Pioneer are at the end of this chapter.

Preventive Maintenance

Preventive maintenance of the Pioneer consists of daily, monthly, and quarterly procedures to ensure that the detectors remain on zero (20.9 for oxygen) in fresh air and are responsive to gas. Appendix B, Gas Detectors, includes preventive maintenance schedules for the detectors supplied with your Pioneer.

Troubleshooting

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

NOTE:

No Power

Symptoms

• All status lights are off.

• The display screen is blank.

Probable causes

• The power wiring is disconnected or misconnected.

• The AC or DC fuse is blown.

• The display cable is disconnected.

Recommended action

1. Verify that the wiring to the power source is correct and secure.

This troubleshooting guide describes controller problems only. See the Troubleshooting guide in the applicable manual insert (Appendix B, Gas Detectors) for problems you may encounter with the detectors.

2. At the Pioneer, verify that the wiring to the AC terminal strip is correct and secure.

3. Check the continuity of the applicable (AC or DC) fuse.

4. Verify that the display cable is connected. The display (ribbon) cable plugs into connectors on the bottom of the display board and directly above the transformer.

5. If the power difﬁculties continue, contact RKI Instruments, Inc., for further instruction.

Pioneer Gas Monitor Operator’s Manual Maintenance • 33

Frequent or Suspect Alarms

Symptoms

• The Pioneer alerts you to frequent or suspect alarms, but the detector’s fresh air readings remain on zero (20.9 for oxygen).

Probable causes

• The Pioneer is experiencing false readings due to Radio Frequency Interference (RFI) or Electromagnetic Interference (EMI).

• The detector wiring is disconnected, misconnected, or intermittent.

Recommended action

1. Verify that the detector wiring is properly shielded (see the Installation section(s) in Appendix B, Gas Detectors.)

2. Verify that the detector wiring is correct and secure.

3. Verify that power and detector wiring is routed through separate conduit hubs on the bottom of the Pioneer housing.

4. Increase the alarm on delay setting in the Instrument Setup program (see Chapter 4, Operation).

5. If the frequent or suspect alarm difﬁculties continue, contact RKI Instruments, Inc., for further instruction.

Flickering Display

Symptoms

• The display readings ﬂicker often.

Probable causes

• The Pioneer is experiencing false readings due to Radio Frequency Interference (RFI) or Electromagnetic Interference (EMI).

• The noise ﬁlter setting is too low.

• The zero suppression setting is too low.

• The display screen is malfunctioning.

Recommended action

1. Verify that the detector wiring is properly shielded (see the Installation section(s) in Appendix B, Gas Detectors.)

2. Verify that the detector wiring is correct and secure.

3. Verify that power and detector wiring is routed through separate conduit hubs on the bottom of the Pioneer housing.

4. Increase the noise ﬁlter setting in the Instrument Setup program (see Chapter 4, Operation).

5. Increase the zero suppression setting in the Instrument Setup pr ogram (see Chapter 4, Operation).

6. If the display difﬁculties continue, contact RKI Instruments, Inc., for further instruction.

34 • Maintenance Pioneer Gas Monitor Operator’s Manual

The Buzzer is not Working Properly

Symptoms

• The buzzer does not sound an audible alarm when the Pioneer goes into an alarm 1, alarm 2, alarm 3, or fail condition.

• The buzzer sounds weak or broken.

Probable causes

• The buzzer is disconnected.

• The buzzer is connected incorrectly.

• The buzzer is malfunctioning.

Recommended action

1. Open the housing door of the Pioneer, then verify that the buzzer wiring to terminals 9 and 10 of the external wiring terminal strip (TB2) is correct and secure.

2. If the buzzer difﬁculties continue, contact RKI Instruments, Inc., for further instruction.

The Reset Switch is not Working Properly

Symptoms

• The buzzer is not silenced when you press the reset switch.

NOTE: Y ou cannot use the r eset switch to silence the buzzer if the alarm silence setting is

OFF in the Instrument Setup program (see Chapter 4, Operation).

• The applicable alarm circuit is not reset when an alarm condition passes and you press the reset switch.

Probable causes

• The reset switch is disconnected.

• The reset switch is connected incorrectly.

• The alarm silence setting is OFF .

• The reset switch is malfunctioning.

Recommended action

1. Enter the Instrument Setup program, and verify that the alarm silence setting is ON (see Chapter 4, Operation).

2. Open the housing door of the Pioneer, then verify that the reset switch wiring to terminals 11 and 12 of the external wiring terminal strip (TB2) is correct and secure.

3. If the reset switch difﬁculties continue, contact RKI Instruments, Inc., for further instruction.

Pioneer Gas Monitor Operator’s Manual Maintenance • 35

Replacing Components

This section describes procedures to replace the analyzer card and fuses. To replace other components of the Pioneer, contact RKI Instruments, Inc., for further information.

Replacing the Analyzer Card

This section describes the procedure to replace the analyzer card.

CAUTION: Removing or plugging in an analyzer card with the power on may damage the

analyzer card or the Pioneer’s main circuit board.

1. Place the Pioneer’s power switch in the OFF position.

2. Open the housing door of the Pioneer, then remove the analyzer card from the u-shaped guide.

3. Plug the replacement analyzer card into the guide.

NOTE: The components of the analyzer card face left when the card is installed correctly.

4. Place the power switch in the ON position, then verify that the pilot light on the replacement analyzer card is ﬂashing.

5. Close and secure the housing door.

Replacing the AC Fuse

This section describes the procedure to replace the AC fuse.

1. Turn off or unplug all incoming power to the Pioneer at the power source end.

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

3. Open the housing door of the Pioneer.

4. Use a ﬂat-blade screwdriver to rotate the fuse holder 1/4 turn counterclockwise. The fuse holder releases from the socket.

5. Remove the fuse holder from the socket, then remove the fuse from the fuse holder.

CAUTION: Verify that the replacement fuse is the same type and rating as the fuse you are

replacing.

6. Install the appropriate replacement fuse in the fuse holder, then place the fuse holder in the socket.

7. Push the fuse holder into the socket, then turn the fuse 1/4 turn clockwise to secure the fuse holder in the socket.

8. Plug in or turn on all incoming power to the Pioneer at the power source end.

9. Place the Pioneer’s power switch in the ON position, then verify that the PILOT light is on.

10. Close and secure the housing door.

36 • Maintenance Pioneer Gas Monitor Operator’s Manual

Replacing the DC Fuse

This section describes the procedure to replace the DC fuse.

1. Turn off or unplug all incoming power to the Pioneer at the power source end.

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

3. Open the housing door of the Pioneer.

4. Remove the DC fuse from the clip holder.

CAUTION: Verify that the replacement fuse is the same type and rating as the fuse you are

replacing.

5. Install the appropriate replacement fuse into the clip holder.

6. Plug in or turn on all incoming power to the Pioneer at the power source end.

7. Place the Pioneer’s power switch in the ON position, then verify that the PILOT light is on.

8. Close and secure the housing door.

Pioneer Gas Monitor Operator’s Manual Maintenance • 37

38 • Maintenance Pioneer Gas Monitor Operator’s Manual

Appendix A: Parts List

Overview

This appendix lists the part numbers and descriptions for replacement parts and accessories offered for the Pioneer Gas Monitor.

Table A-1: Parts List for the Pioneer Gas Monitor

Part No. Description

18-0003RK Conduit Plug (3/4 in. NPT) 18-0107RK Conduit Hub (3/4 in.) 43-0440RK Reset Switch 43-4138RK AC Fuse, 220V (1/2 amp; 250V) 43-4140RK AC Fuse, 115V (1 amp; 250V) 43-4165RK DC Fuse (3 amps; 250V) 52-1016RK Buzzer 57-0004RK Analyzer Card 71-0027RK Pioneer Gas Monitor Operator’s Manual (this document)

Pioneer Gas Monitor Operator’s Manual Parts List • 39

40 • Parts List Pioneer Gas Monitor Operator’s Manual

Appendix B: Gas Detectors

Overview

This appendix includes manual inserts for the gas detectors/transmitters originally shipped with your Pioneer Gas Monitor. If you add an additional gas detector/ transmitter at a later date, make sure you add the applicable manual insert to this appendix to keep your manual up to date.

Gas Detection Options for the Pioneer Gas Monitor

Table B-1 lists gas detectors and transmitters offered by RKI Instruments, Inc. for the Pioneer Gas Monitor. The table lists the target gas(es), method of detection, part number, and manual insert part number for each detector/transmitter.

Table B-1: Gas Detection Options for the Pioneer Gas Monitor

Detector/

Transmitter

Target Gas(es)

LEL Combustible gas

LEL/PPM Combustible gas

LEL Combustible gas

Oxygen Oxygen

Method of

Detection

Diffusion Diffusion Diffusion Diffusion Diffusion

Det./Trans.

Part No.

61-1000RK 71-0027RK-01 61-1010RK 71-0027RK-01 65-2400RK 71-0027RK-10

65-2502RK 65-2504RK

Manual Insert

Part No.

71-0027RK-02 71-0027RK-09

CO Carbon monoxide Diffusion 65-2430RK 71-0027RK-07

S Hydrogen sulﬁde Diffusion 65-2420RK 71-0027RK-08

GD-K8A GD-K7D

Various toxic gases Various toxic gases

Diffusion

Sample-draw

GD-K8A-XXXX GD-K7D-XXXX

71-0027RK-03

71-0027RK-05

Internal ampliﬁer type.

Remote ampliﬁer type.

Add -01 for the oxygen detector/transmitter that includes a vent patch that prevents water from entering the sensor in case of hosing down or splashing.

See the applicable manual insert for a list of target gases.

Replace “XXXX” with the formula of the target gas. For example, GD-K8A-PH3 for the phosphine version.

Pioneer Gas Monitor Operator’s Manual Gas Detectors • 41

42 • Gas Detectors Pioneer Gas Monitor Operator’s Manual

Combustible Gas Transmitter

Overview

This detection insert describes the combustible gas transmitter. This insert also describes how to install, start up, maintain, and calibrate the transmitter and run the Channel Setup program. A parts list at the end of this insert lists replacement parts and accessories for the combustible gas transmitter.

Speciﬁcations

Table 1 lists speciﬁcations for the combustible gas transmitter. See the speciﬁcations in Chapter 1, Introduction, for speciﬁcations that apply to the Pioneer Gas Monitor.

Table 1: Speciﬁcations

Target Gas Combustible 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* Alarm 1 Setpoint 10% LEL* Alarm 2 Setpoint 20% LEL* Alarm 3 Setpoint 50% LEL* Response Time 90% in 45 seconds

* These speciﬁcations represent RKI standard settings; however, you can adjust them in the Channel Setup program.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 1

Description

This section describes the components of the combustible gas transmitter . The transmitter consists of the combustible gas detector, ampliﬁer, and junction box.

Combustible gas amplifier

Potentiometer

(factory set)

Securing screw (2)

Test point (+)

Potentiometer

(factory set)

Test point (-)

GND

24V

TP+

4-20

RED

WHT GRN

SENSOR POWER/SIG

BLK

TP-

Interconnect terminal strip

Jumper pins

(factory use only)

Span potentiometer

Zero potentiometer

Reducer

(3/4 in. x 1/2 in.)

Combustible gas detector

Figure 1: Combustible Gas Transmitter Component Location

Combustible Gas Detector

The combustible gas detector includes the sensing elements, ﬂame arrestor, detector housing, and detector leads.

Sensing elements

Two sensing elements are protected within the detector assembly. Through a series of thermal and electronic reactions, these elements produce an electrical output that is proportional to the detection range of the transmitter.

Flame arrestor

The porous ﬂame arrestor allows the target gas to diffuse into the detector assembly and contact the sensing elements. The ﬂame arrestor also contains sparks within the detector.

Combustilbe Gas Transmitter • 2 Pioneer Operator’s Manual (PRELIMINARY)

Detector housing

The sensing elements and ﬂame arrestor are installed within the detector housing. Mounting threads (1/2 in. NPT) at the top of the detector allow you to mount the combustible gas detector into the bottom conduit hub of the junction box. A rainshield screws onto the bottom of the detector. The rainshield helps protect the detector from debris in the monitoring environment.

Detector leads

Four color-coded leads extend from the top of the detector. The leads allow you to connect the combustible gas detector to the ampliﬁer.

Ampliﬁer

The ampliﬁer converts the electrical output from the detector to a 4 to 20 mA signal (that is proportional to the detection range) and transmits the signal to the Pioneer. 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 combustible gas detector to the ampliﬁer and the ampliﬁer to the Pioneer Gas Monitor.

NOTE: The combustible gas detector is factory-wired to the ampliﬁer. See the

Installation section of this insert for all wiring procedures related to the transmitter.

Span potentiometer

The span potentiometer is near the bottom of the ampliﬁer. Of the two potentiometers near the bottom of the ampliﬁer , the span potentiometer is farthest to the left. Use the span potentiometer to adjust the transmitter’s response output during the calibration procedure.

Zero potentiometer

The zero potentiometer is to the right of the span potentiometer. Use the zero potentiometer to adjust the transmitter’s target gas-free output during the start-up and calibration procedures.

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. The test points produce a 100 to 500 mV output that is proportional 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.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 3

Junction Box

Use the junction box to install the combustible gas transmitter at a mounting site that is remote from the Pioneer. The junction box also protects the ampliﬁer 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 Pioneer (top hub).

NOTE: The combustible gas detector and ampliﬁer are factory-mounted to the

junction box.

Use the junction box’s two mounting 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.

Combustilbe Gas Transmitter • 4 Pioneer Operator’s Manual (PRELIMINARY)

Installation

This section describes procedures to mount the combustible gas transmitter in the monitoring environment and wire the transmitter to the Pioneer Gas Monitor.

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.

2.75 in.

(7.0 cm)

Note: The junction box is

4.6 in. (11.7 cm) deep.

5.46 in.

(13.9 cm)

7.7 in. (max.) (19.6 cm)

2.3 in.

(5.8 cm)

5.2 in.

(13.2 cm)

Figure 2: Mounting the Combustible Gas Transmitter

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 5

If the combustible gas 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 combustible gas detector through the bottom conduit hub of the junction box.

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

5. At the monitoring site, use 1/4 in. screws through the junction box’s two mounting holes to secure the junction box to a vertical surface.

CAUTION: Mount the combustible gas transmitter with the detector facing down (see Figure 2.)

Wiring the Combustible Gas Transmitter to the Pioneer

WARNING: Always verify that the Pioneer’s power switch is in the OFF position

before you make wiring connections.

1. Place the Pioneer’s power switch in the OFF position.

2. Remove the junction box cover.

3. 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.

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

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

• Connect the positive wire to the terminal labeled 24V + .

• Connect the feedback wire to the terminal labeled 4/20 FB .

• Connect the negative wire to the terminal labeled GND .

CAUTION: Leave the ground wire insulated and disconnected at the transmitter. You will

connect the opposite end of the cable’s ground wire at the Pioneer.

6. Secure the junction box cover to the junction box.

7. Route the cable or wires leading from the combustible gas transmitter through one of the conduit hubs on the bottom of the Pioneer 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 Pioneer.

Combustilbe Gas Transmitter • 6 Pioneer Operator’s Manual (PRELIMINARY)

8. Connect the wires to the detector terminal strip of the applicable analyzer card as shown in Figure 3. The detector terminal strip is the 7-point terminal strip (terminals 1 through 7) on the card.

7 Gnd 6 24 V 5 4-20 4 RED 3 WHT

2 GRN

NOT USED

1 BLK

Detector Terminal Strip

(on Pioneer Analyzer Card)

GND

24V

TP+

4-20

RED

WHT

GRN

SENSOR POWER/SIG

BLK

TP-

Black

Green

White

Red

Figure 3: Wiring the Combustible Gas Transmitter to the Pioneer Gas Monitor

9. At the Pioneer, connect the cable’s ground wire to an available chassis ground. The grounding screw on each conduit hub is an example of a chassis ground.

10. At the Pioneer, insert 3/4 in. NPT conduit plugs in any unused conduit hubs. See “Parts List” on page 28 for ordering information.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 7

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 insert.

2. Verify that the power wiring is correct and secure (see Chapter 3, Installation and Start Up.)

3. Turn on or plug in the incoming power at the power source end, then place the Pioneer’s power switch in the ON position.

4. Verify that the main PILOT light is on and the pilot light for each analyzer card is ﬂashing.

CAUTION: Allow the detector to warm up for 15 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 environment, 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 gas).

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

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

4. Plug the voltmeter leads into the test points on the ampliﬁer. Plug the positive lead into the test point labeled TP+ ; plug the negative 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.

Combustilbe Gas Transmitter • 8 Pioneer Operator’s Manual (PRELIMINARY)

Channel Setup Program

This section describes the Pioneer’s Channel Setup program for the combustible gas transmitter. You can display and change the following channel settings with the Channel Setup program.

• Channel Status

• Target Gas, Unit of Measure, and Fullscale Setting

• Channel Type and Measuring Options

• Relay 3 Assignment

• Alarm Setpoints and Alarm Type (rising or falling)

NOTE: Channels that are included with the original shipment of the Pioneer are setup at

the factory. If you are adding a channel to an existing Pioneer, you need to establish the channel settings in this program.

Navigating through the Channel Setup Program

Table 2: Program Button Functions for the Channel Setup Program

Button Function

ESCAPE • Moves you backward through the program.

• Cancels changes made to the program

settings.

UP/YES • Updates the setting that is displayed on the

display screen.

• Saves changes made to the program settings.

DOWN/NO • Updates the setting that is displayed on the

display screen.

• Enters the program (with the ENTER button).

• Saves changes made to the program settings.

ENTER • Moves you forward through the program.

• Enters the program (with the DOWN/NO

button).

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 9

Running the Channel Setup Program

This section describes how to enter the program, display and change program settings, and save or cancel changes to the program settings.

Entering the channel setup program

1. Open the housing door, and locate the program buttons to the right of the display screen.

2. Press the ENTER and DOWN/NO buttons simultaneously three times. The Channel Setup program screen appears.

ersi

V Cha ESCA A

NYTO

on X.XX

ne tSen

pul Abor t REK

Nex t

NOTE: Once you enter the Channel Setup program, the status lights, buzzer, and relays

are disabled until you exit the program.

3. Press the UP/YES, DOWN/NO, or ENTER button to continue. The program asks if you want to setup Channel 1.

C ESCAE t UP/D

NTER

4. To display or change settings for Channel 1, press the ENTER button (the program displays the Channel Status screen.) To continue to Channel 2 settings, press the UP/YES button. To go to Channel 4 settings, press the DOWN/NO button.

NOTE: The screens illustrated in this section are examples and describe the Channel

Setup program for Channel 1.

ann

P N

angeC

tpu

Now

ann

Combustilbe Gas Transmitter • 1 0 Pioneer Operator’s Manual (PRELIMINARY)

Channel status screen

This screen indicates the status of Channel 1. For installed channels the default setting is

ACTIVE/ONLINE . For empty channels, the default setting is NO SENSOR/AMP . The

third setting, SILENCED/OFFLINE , displays the gas reading as XXXX; and the buzzer, status lights, and relays are disabled for the channel.

hanne l

C ACTIVE/

1 N

LINE

• To accept the channel status setting and continue the program, press the ENTER button.

The program displays the Fullscale Reading, Unit of Measure, and Target Gas screen.

• To update the channel status setting:

1. Use the UP/YES and DOWN/NO buttons to change the setting.

2. Press the ENTER button to accept the new setting and continue the program. The program displays the Fullscale Reading, Unit of Measure, and Target Gas screen.

NOTE: If you select a channel status of NO SENSOR/AMP , the program continues with

the next channel.

Fullscale reading, unit of measure, and target gas screen

This screen indicates the fullscale reading, unit of measure, and target gas for Channel 1. The default settings for the combustible gas channel are 100 (fullscale reading), %LEL (unit of measure), and COMB (target gas).

00 %

LEL

• To accept the settings and continue the program, press the ENTER button three times. The program displays the Channel Type and Measuring Options screen.

• To update the target gas, unit of measure, and/or fullscale reading setting:

1. Use the ENTER and ESCAPE buttons to select the setting you want to change.

(The setting ﬂashes when it is selected.)

2. Use the UP/YES and DOWN/NO buttons to change the setting.

3. Press the ENTER button until the program displays the Channel Type and

Measuring Options screen.

NOTE: If you update the target gas, turn the Pioneer’s power switch OFF and then ON

again after you return to normal operation.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 11

Channel type and measuring options screen

This screen indicates the channel type and measuring options for Channel 1. The default setting for the channel type (input) setting is 4-20 Remote . The default setting for the measuring options (range) setting is LEL ONLY .

INPUT:

RANG

E:LE

4-20Re

LONLY

• To accept the settings and continue the program, press the ENTER button. The program displays the Relay 3 Assignment screen.

• To update the channel type setting:

1. Use the UP/YES or DOWN/NO button to change the setting.

2. Press the ENTER button to accept the new setting and continue the program. The program displays the Relay 3 Assignment screen.

NOTE: If the channel type setting is 4-20 Remote , the measuring options setting is

LEL ONLY and is not adjustable.

Relay 3 assignment screen

This screen indicates the assignment of the alarm 3 relay for Channel 1. If you select

Alarm 3 , then the alarm 3 relay activates if Channel 1 goes into an alarm 3 condition.

If you select Fail Alarm , then the alarm 3 relay de-energizes if Channel 1 goes into a fail condition.

NOTE: If you assign the alarm 3 relay as the channel’s fail relay, the status light and

buzzer still indicate visual and audible alarms for an alarm 3 condition.

hanne l

C Rela

Alarm

igned

• To accept the relay 3 assignment setting and continue the program, press the ENTER button.

The program displays the Fail Setpoint screen.

• To update the relay 3 assignment setting:

1. Use the UP/YES or DOWN/NO button to change the setting.

2. Press the ENTER button to accept the new setting and continue the program. The program displays the Fail Setpoint screen.

Combustilbe Gas Transmitter • 1 2 Pioneer Operator’s Manual (PRELIMINARY)

Fail setpoint screen

This screen indicates the setpoint and alarm type for the fail alarm. The setpoint is the display reading at which the alarm is activated. The alarm type controls how the alarm is activated (rising or falling readings).

The default setting for the fail setpoint for the combustible gas channel is -10 . The default setting for the alarm type is FALL .

NOTE: If you selected a measuring options setting of PPM/LEL , you can select PPM or

LEL fail and alarm setpoint settings.

anne l 1 Fa i l Alarm

LEL

FALL

• To accept the settings and continue the program, press the ENTER button two times. The program displays the Alarm 1 Setpoint screen.

• To update the fail setpoint setting:

1. Use the UP/YES and DOWN/NO buttons to change the fail setpoint setting.

2. Press the ENTER button two times to accept the new setting and continue the

program.

The program displays the Alarm 1 Setpoint screen.

• To update the alarm type setting:

1. Press the ENTER button to select the alarm type setting. (The setting ﬂashes when

it is selected.)

2. Use the UP/YES or DOWN/NO button to change the setting.

3. Press the ENTER button to accept the new setting and continue the program. The program displays the Alarm 1 Setpoint screen.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 13

Alarm 1 setpoint screen

This screen indicates the setpoint and alarm type for Alarm 1. The default setting for the alarm 1 setpoint for the combustible gas channel is 10 . The default setting for the alarm type is RISE .

anne l 1 A larm

LEL

RISE

• To accept the settings and continue the program, press the ENTER button two times. The program displays the Alarm 2 Setpoint screen.

• To update the alarm 1 setpoint:

1. Use the UP/YES and DOWN/NO buttons to change the setpoint.

2. Press the ENTER button two times to accept the new setting and continue the

program.

The program displays the Alarm 2 Setpoint screen.

• To update the alarm type setting:

1. Press the ENTER button to select the alarm type setting. (The setting ﬂashes when

it is selected.)

2. Use the UP/YES or DOWN/NO button to change the setting.

3. Press the ENTER button to accept the new setting and continue the program. The program displays the Alarm 2 Setpoint screen.

Alarm 2 setpoint screen

This screen indicates the setpoint and alarm type for Alarm 2. The default setting for the alarm 2 setpoint for the combustible gas channel is 20 . The default setting for the alarm type is RISE .

anne l 1 A larm

LEL

RISE

• To accept the settings and continue the program, press the ENTER button two times. The program displays the Alarm 3 Setpoint screen.

• To update the alarm 2 setpoint:

1. Use the UP/YES and DOWN/NO buttons to change the setpoint.

2. Press the ENTER button two times to accept the new setting and continue the

program.

The program displays the Alarm 3 Setpoint screen.

• To update the alarm type setting:

1. Press the ENTER button to select the alarm type setting. (The setting ﬂashes when

it is selected.)

2. Use the UP/YES or DOWN/NO button to change the setting.

3. Press the ENTER button to accept the new setting and continue the program. The program displays the Alarm 3 Setpoint screen.

Combustilbe Gas Transmitter • 1 4 Pioneer Operator’s Manual (PRELIMINARY)

Alarm 3 setpoint screen

This screen indicates the setpoint and alarm type for Alarm 3. The default setting for the alarm 3 setpoint for the combustible gas channel is 50 . The default setting for the alarm type is RISE .

anne l 1 A larm

50 %

LEL

RISE

• To accept the settings and continue the program, press the ENTER button two times. The program begins channel setup for Channel 2.

• To update the alarm 3 setpoint:

1. Use the UP/YES and DOWN/NO buttons to change the setpoint.

2. Press the ENTER button two times to accept the new setting and continue the

program.

The program begins channel setup for Channel 2.

• To update the alarm type setting:

1. Press the ENTER button to select the alarm type setting. (The setting ﬂashes when

it is selected.)

2. Use the UP/YES or DOWN/NO button to change the setting.

3. Press the ENTER button to accept the new setting and continue the program. The program begins channel setup for Channel 2.

NOTE: To exit the Channel Setup program, press the ESCAPE button. The Channel

Setup Exit screen displays.

Channel setup exit screen

This screen saves or cancels any changes you made in the Channel Setup program.

Abor t Se

Save & Ex i

Nex t

APE

UP/DOWN

ENTER

• To save changes and exit the program, press the UP/YES or DOWN/NO button.

The program displays a conﬁrmation message, then the normal screen appears. The Pioneer is in normal operation.

• To cancel changes and exit the program, press the ESCAPE button.

The program displays a conﬁrmation message, then the normal screen appears. The Pioneer is in normal operation.

• To setup another channel , press the ENTER button.

The program asks if you want to setup the next channel. Press the ENTER button to continue.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 15

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

1. Verify that the pilot light on the applicable analyzer card is ﬂashing. If the pilot light is

NOTE: If the Pioneer’s main PILOT light is not on, see the Troubleshooting guide in

not ﬂashing, see the following troubleshooting guide in this insert.

Chapter 5, Maintenance.

2. Verify a display reading of 0 %LEL. 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.

Preparing for the response test

1. Verify that the display reading(s) for the channel(s) you plan to test is 0. If the display reading(s) is not zero, set the zero reading of the applicable

transmitter(s) as described in the Start Up section of this insert, then continue this procedure.

2. Assemble the calibration kit as described in the Calibration section of this insert.

NOTE: Do not screw the regulator into the calibration cylinder at this time.

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

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

TP-

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

Combustilbe Gas Transmitter • 1 6 Pioneer Operator’s Manual (PRELIMINARY)

Entering the Calibrate program

1. Open the Pioneer’s housing door, and locate the program buttons to the right of the display screen.

2. Press the ENTER and UP/YES button simultaneously three times. The Calibrate program screen appears.

ersi

V Cal ESCA A

NYTO

on X.XX

irateb

Abort REK

Nex t

NOTE:

Once you enter the Calibrate program, the status lights, buzzer, and relays are disabled until you exit the Calibrate program.

The Pioneer automatically exits the Calibrate program if you do not exit the program before the calibration time-out setting expires. You can display and change the calibration time-out setting in the Instrument Setup program (see Chapter 4, Operation.)

3. Press the UP/YES, DOWN/NO, or ENTER button to continue. The Select screen appears. The ﬁrst line (channel 1) is ﬂashing.

Selecte

NOTE:

The example used in this procedure describes a response test for Channels 3 and 4.

4. Press the DOWN/NO button two times. The third line (channel 3) is ﬂashing.

5. Press the ENTER button to “select” Channel 3, then press the DOWN/NO button.

6. Press the ENTER button to “select” Channel 4, then press the DOWN/NO button.

NOTE:

The description for Channels 3 and 4 changes to

4-20 Monitor

when you “select”

Channels 3 and 4.

The Channels Selected screen appears.

uhav

these Cha

eSelecte

nels:

34,

ENTER Nex

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 17

7. Verify that you selected the correct channel(s), then press the ENTER button to continue.

The Choose Calibration screen appears.

Choose Ca

Zer Spa ENTER Nex

NOTE

: If one or more of the channels you selected on the Select screen is an oxygen

channel, then the Choose Calibration screen appears as follows.

Choose Ca

ENT

8. Verify that the then press the ENTER button to continue. If the press the DOWN/NO button, then press the ENTER button.

The Calibration screen appears.

9. Press the ENTER button. The Apply Gas screen appears.

Span Proceed

C A

C C C C

(

line is ﬂashing [or

1 2

l ocee ocee

l Oxygen OSpan

Nex

(

50 COMB 50 COMB

ibr

d d

ibr

neg

Sel ec t ed

Spa

Zero

Span (Oxygen Zero) Span Proceed

)

line is not ﬂashing,

) )

detceleStoN

if applicable],

E ENTER

10. Press the ENTER button. The Span screen appears.

APE

Pr vi u

XXX XXX

0 0

ly G

pply

NTER

Spa

s as

Combustilbe Gas Transmitter • 1 8 Pioneer Operator’s Manual (PRELIMINARY)

erforming the response test

1. Screw the regulator into the calibration cylinder.

NOTE: Once you introduce the test sample to the transmitter, the Span screen “freezes”

and displays each “selected” channel’s highest reading. This feature enables you to verify the readings at the Pioneer in addition to the “local” test at the transmitter.

2. When the reading on the voltmeter stabilizes, verify that the reading is within ± 10% of the response reading you determined earlier.

NOTE: If the readings are not within ± 10% of the correct response reading, calibrate the

affected transmitters as described in the Calibration section of this insert.

3. Unscrew the regulator from the calibration cylinder, then disassemble the calibration kit as described in the Calibration section of this insert.

NOTE: If the Pioneer’s display reading(s) is above the alarm 1 setpoint when you return

to the normal screen, the Pioneer will initiate the appropriate alarm condition. You can view the reading(s) of the “selected” channels on the Fresh Air screen in the Calibrate program.

T o display the Fr esh Air screen, press the ESCAPE button, next pr ess the UP/YES button, then press the ENTER button.

4. Press the ESCAPE button until the Save screen appears.

Abor t Se

Save & Ex i

Nex t

APE

UP/DOWN

ENTER

5. Press the ESCAPE button. A conﬁrmation message displays, then the normal screen appears.

TRUM N

NS NOT PREV

UVA

S UAVEDS

SING

NOTE: The Pioneer does not save calibration values for remote transmitters. When

calibrating the transmitter, you perform calibration at the transmitter; therefore, it is not necessary to save calibration values at the Pioneer.

The purpose of entering the Calibrate program when performing this response test is to disable the status lights, buzzer, and relays and so you can view the response reading(s) on the Span screen.

Quarterly

Calibrate the combustible gas transmitter as described in the Calibration section of this insert.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 19

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

Troubleshooting guide in Chapter 5, Maintenance, for problems you may encounter with the Pioneer Gas Monitor.

Fail Condition

Symptoms

• The FAIL light is on.

• The buzzer is sounding a steady tone.

• The fail relay is de-energized.

• The display reading is ﬂashing.

Probable causes

• The analyzer card is disconnected or misconnected.

• The transmitter wiring is disconnected or misconnected.

• The transmitter is malfunctioning.

Recommended action

1. Verify that the analyzer card is installed correctly and that the pilot light on the analyzer card is ﬂashing. The components of the analyzer card face left when the card is installed correctly.

2. Verify that the transmitter wiring is correct and secure. The Installation section of this insert describes transmitter wiring connections.

3. Calibrate the transmitter as described in the Calibration section of this insert.

4. If the fail condition continues, replace the detector as described later in this section.

5. If the fail condition continues, contact RKI Instruments, Inc., for further instruction.

Combustilbe Gas Transmitter • 2 0 Pioneer Operator’s Manual (PRELIMINARY)

Slow or No Response/Difﬁcult or Unable to Calibrate

Symptoms

• The transmitter responds slowly or does not respond during the monthly response test.

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

• The transmitter requires frequent calibration.

NOTE: Under “normal” circumstances, the transmitter requires calibration once every

three months. Some applications may require a more frequent calibration schedule.

Probable causes

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

• The transmitter is malfunctioning.

Recommended action

1. Verify that the calibration cylinder contains an adequate supply of a fresh test sample.

2. If the calibration/response difﬁculties continue, replace the detector as described later in this section.

3. If the calibration/response difﬁculties continue, contact RKI Instruments, Inc., for further instruction.

No Display Reading

Symptoms

• The transmitter is installed, but the display screen is blank for that channel.

NOTE: If the display screen is blank for all channels, see the troubleshooting guide in

Chapter 5, Maintenance.

Probable causes

• The channel status setting is set at NO SENSOR/AMP.

Recommended action

1. Enter the Channel Setup program, and change the channel status setting to ACTIVE/ ONLINE or SILENCED/OFFLINE.

2. If the display reading difﬁculties continue, contact RKI Instruments, Inc., for further instruction.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 21

Replacing Components of the Combustible Gas Transmitter

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

Replacing the combustible gas detector

1. Place the Pioneer’s power switch in the OFF position.

2. Remove the junction box cover.

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

4. Unscrew the detector from the junction box.

5. 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.

6. Connect the detector leads to the detector terminal strip as shown in Table 3 and Figure 3, Wiring the Combustible Gas Transmitter to the Pioneer Gas Monitor.

Table 3: Reconnecting the Combustible Gas Detector to the Ampliﬁer

Detector Lead

Red SENSOR RED White SENSOR WHT Green SENSOR GRN

Black SENSOR BLK

7. Place the Pioneer’s power switch in the ON position.

CAUTION: Allow the replacement detector to warm up for 15 minutes before you continue with

the next step.

8. Calibrate the replacement detector as described in the Calibration section of this insert.

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

Replacing the ampliﬁer

1. Place the Pioneer’s power switch in the OFF position.

2. Remove the junction box cover.

3. Disconnect the detector leads from the interconnect terminal strip.

4. 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.

5. Remove the ampliﬁer.

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

7. Use the two screws you removed in step 4 to secure the ampliﬁer to the junction box.

Interconnect Terminal Strip

Ampliﬁer

Combustilbe Gas Transmitter • 2 2 Pioneer Operator’s Manual (PRELIMINARY)

8. Reconnect the wiring from the Pioneer to the interconnect terminal strip as shown in Table 4 and Figure 3, Wiring the Combustible Gas Transmitter to the Pioneer Gas Monitor.

Table 4: Reconnecting the Combustible Gas Ampliﬁer to the Pioneer Gas Monitor

Ampliﬁer

Interconnect Terminal Strip

Pioneer Analyzer Card

GND Gnd (Terminal 7)

4-20 4-20 (Terminal 5) 24V 24 V (Terminal 6)

9. Reconnect the detector leads to the interconnect terminal strip as shown in Table 5 and Figure 3, Wiring the Combustible Gas Transmitter to the Pioneer Gas Monitor.

Table 5: Reconnecting the Combustible Gas Detector to the Ampliﬁer

Detector Lead

Interconnect Terminal Strip

Ampliﬁer

Red SENSOR RED White SENSOR WHT Green SENSOR GRN

Black SENSOR BLK

10. Place the Pioneer’s power switch in the ON position.

CAUTION: Allow the detector to warm up for 15 minutes before you continue with the next step.

11. Calibrate the combustible gas transmitter as described in the Calibration section of this insert.

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 23

Calibration

This section describes how to calibrate the combustible gas transmitter. It includes procedures to prepar e for calibration, enter the Calibrate program, set the zer o reading, set the response reading, and return to normal operation.

WARNING: The Pioneer is not an active gas monitoring device during the calibration

procedure.

Preparing for Calibration

1. Slide the calibration cup over the bottom of the combustible gas detector, then secure the calibration cup to the detector with the two screws.

2. Use the sample tubing to connect the regulator to the calibration cup.

NOTE: Do not screw the regulator into the zero air calibration cylinder at this time.

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-.

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

Entering the Calibrate Program

1. Open the housing door of the Pioneer, and locate the program buttons to the right of the display screen.

2. Press the ENTER and UP/YES buttons simultaneously three times. The Calibrate program screen appears.

ersi

V Cal ESCA A

NYTO

NOTE: Once you enter the Calibrate program, the status lights, buzzer, and relays are

disabled until you exit the Calibrate program. The Pioneer automatically exits the Calibrate program if you do not exit the

program before the calibration time-out setting expires. You can display and change the calibration time-out setting in the Instrument Setup program (see Chapter 4, Operation.)

on X.XX

irateb

Abort REK

Nex t

Combustilbe Gas Transmitter • 2 4 Pioneer Operator’s Manual (PRELIMINARY)

3. Press the UP/YES, DOWN/NO, or ENTER button to continue. The Select screen appears. The ﬁrst line (channel 1) is ﬂashing.

C C C C

H1 H H H

Selecte

NOTE: The example used in this procedure describes calibration for Channels

1, 2, and 3.

4. Press the ENTER button to “select” Channel 1, then press the DOWN/NO button. The second line (channel 2) is ﬂashing.

5. Repeat step 4 to “select” Channels 2 and 3.

NOTE: The description for Channels 1, 2, and 3 changes to 4-20 Monitor when you

“select” Channels 1, 2, and 3.

6. Press the DOWN/NO or UP/YES button until the Channels Selected screen appears.

uhav

these Cha

,2,

ENTER Nex

eSelecte

nels:

7. Verify that you selected the correct channel(s), then press the ENTER button to continue.

The Choose Calibration screen appears.

Choose Ca Zer Spa

o n

Pr Pr

ocee

ENTER Nex

ibr

d d

NOTE: If one or more of the channels you selected on the Select screen is an oxygen

channel, then the Choose Calibration screen appears as follows.

Choose Ca

(

Oxygen OSpan

Nex

ENT

ibr

neg

Spa

Zero

)

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 25

8. Verify that the Zero Proceed line is ﬂashing [or Zero (Oxygen Span) if applicable], then press the ENTER button to continue. If the Zero Proceed line is not ﬂashing, press the UP/YES button, then press the ENTER button.

The Fresh Air screen appears. The readings displayed on the Fresh Air screen are the current gas readings. The asterisk (*) to the right of each reading indicates that you cannot adjust this reading at the Pioneer.

XXX

ENTER

Adju

hAir st

CAUTION: Do not press the ENTER button at this time.

Setting the Zero Reading

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

2. When the reading on the voltmeter stabilizes, 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).

3. 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.

2. When the reading on the voltmeter stabilizes, 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.

3. Unscrew the regulator from the calibration cylinder.

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

Combustilbe Gas Transmitter • 2 6 Pioneer Operator’s Manual (PRELIMINARY)

Returning to Normal Operation

1. Loosen the two screws that secure the calibration cup to the detector, then remove the cup from the bottom of the detector.

NOTE: For convenience, leave the components of the calibration kit connected by the

sample tubing.

2. Secure the junction box cover to the junction box.

NOTE: If the reading(s) is above the alarm 1 setpoint when you return to the normal

screen, the Pioneer will initiate the appropriate alarm condition. You can view the current reading(s) of the “selected” channels on the Fresh Air screen.

3. Press the ESCAPE button three times. The Save screen appears.

APE

UP/DOWN

ENTER

4. Press the ESCAPE button. A conﬁrmation message displays, then the normal screen appears.

TRUM N

NS NOT PREV

NOTE: Because you performed calibration at the transmitter, it is not necessary to save

calibration values at the Pioneer . The Pioneer does not save calibration values for remote transmitters.

The purpose of entering the Calibrate program is to disable the status lights, buzzer, and relays during calibration and so you can view the current reading(s) on the Fresh Air screen.

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

6. Verify that the applicable display reading(s) decreases and stabilizes at 0 %LEL.

Abor t Se

Save & Ex i

Nex t

UVA

UAVEDS

SING

Pioneer Operator’s Manual (PRELIMINARY) Combustible Gas Transmitter • 27

Parts List

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

Table 6: Parts List

Part Number Description

06-1248RK Sample tubing (3/16 in. x 5/16 in.; specify length when ordering) 18-0003RK Conduit plug (3/4 in. NPT) 18-0405RK-01 Junction box (without cover, pre-drilled for ampliﬁer) 18-0406RK Junction box cover (cover only) 57-0004RK Analyzer card 57-1050RK Ampliﬁer (specify target gas when ordering) 61-0140RK Combustible gas detector (specify target gas when ordering) 65-2400RK Combustible gas transmitter (includes detector and ampliﬁer;

specify target gas when ordering) 71-0027RK-10 Combustible Gas Transmitter Manual Insert (this document) 81-0007RK-01 Calibration cylinder (50% LEL Hexane; 34 liter) 81-0012RK-01 Calibration cylinder (50% LEL Methane; 34 liter) 81-0076RK-01 Zero air calibration cylinder (34 liter) 81-1003RK Regulator, 0.5 liter/minute; continuous ﬂow

(for 17 and 34 liter calibration cylinders) 81-1110RK Calibration cup

Combustilbe Gas Transmitter • 2 8 Pioneer Operator’s Manual (PRELIMINARY)

Pioneer Hydrogen Transmitter Technical Notice

Although this Pioneer manual insert was written for the combustible gas LEL transmitter, the operational instructions are the same for the hydrogen transmitter with the exception of the sensor wiring and the following specifications:

- Model: Pioneer hydrogen transmitter, 65-2440RK

- Gas: Hydrogen

- Measuring range: 0 - 2000 ppm

- Alarm points: Alarm 1 200 ppm Alarm 2 500 ppm Alarm 3 1000 ppm

- Calibration gas: 1000 ppm Hydrogen

- Sensor: 61-0160RK

- Transmitter: 57-1071RK

Please see the attached wiring diagram for the sensor wiring. The wiring from the transmitter to the Pioneer controller is the same as shown in the following insert.

Beacon 800 Oxygen Detection

65-2507RK Technical Notice

Although this detction insert was written for the standard oxygen transmitter, 65-2504RK, the operational instructions are the same for the 65-2507RK transmitter with the following differences:

- Model: Oxygen transmitter, 65-2507RK

- Measuring range: 0 - 25% (same)

- Sensor: 65-2506RK

- Amplifier: 57-1061RK

The wiring from the sensor to the amplifier and the amplifier to the Beacon 800 controller is the same as shown in this manual.

Oxygen T ransmitter

Overview

This detection insert describes the oxygen transmitter. This insert also describes how to install, start up, maintain, and calibrate the transmitter and run the Channel Setup program. A parts list at the end of this insert lists replacement parts and accessories for the oxygen transmitter.

Speciﬁcations

Table 1 lists speciﬁcations for the oxygen transmitter. See the speciﬁcations in Chapter 1, Introduction, for speciﬁcations that apply to the Pioneer Gas Monitor.

Table 1: Speciﬁcations

Target Gas Oxygen (O2) Sampling Method Diffusion

Signal Output 4 to 20 mA Detection Range 0 to 25.0% VOL (by volume)* Alarm 1 Setpoint 19.5% VOL (decreasing)* Alarm 2 Setpoint 17.0% VOL (decreasing)* Alarm 3 Setpoint 23.5% VOL (increasing)* Response Time 90% in 30 seconds

* These speciﬁcations represent RKI standard settings; however, you can adjust them in the Channel Setup program.

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 1

Description

This section describes the components of the oxygen transmitter. The transmitter consists of the oxygen detector and ampliﬁer. The oxygen detector and ampliﬁer are housed in separate junction boxes. The junction boxes are connected by a 3/4 in. closed nipple.

Zero

Span potentiometer

Amplifier type selector

Detector terminal strip

TOXIC

OXY

potentiometer

Test point (-)

Interconnect terminal strip

Securing screw (2)

Test point (+)

3/4 in. closed nipple

Oxygen amplifier

Detector junction box

Oxygen

Sensor

Sensor terminal block

Sensor connector

Figure 1: Oxygen Transmitter Component Location

Oxygen Detector

The oxygen detector includes the sensor, sensor connector, sensor terminal block, and detector junction box (see Figure 1.)

Oxygen sensor

The oxygen sensor is installed within the detector junction box. Through a series of chemical and electronic reactions, the cell produces an electrical output that is proportional to the detection range of the transmitter.

Detector connector

The cable that extends from the sensor terminates in a socket. A 7-pin male connector plugs into the socket to complete the detector connector assembly. Two color-coded leads extend from the detector connector.

Oxygen Transmitter • 2 Pioneer Operator’s Manual (PRELIMINARY)

Sensor terminal block

The sensor terminal block is the two-point terminal block that is located in the detector junction box. Use the sensor terminal block to connect the oxygen detector to the ampliﬁer.

NOTE:

Detector junction box

The rectangular junction box allows you to install the oxygen detector at a mounting site that is remote from the Pioneer, and it protects the detector and wiring connections.

A hub at the top of the junction box allows you to r oute the wiring from the detector to the ampliﬁer. The front of the junction box is the junction box cover. It includes a diffusion port that allows oxygen in the surrounding environment to contact the oxygen sensor. Two slot-head screws secure the cover to the junction box. You can loosen these screws to access the interior of the junction box.

The oxygen sensor is factory-wired to the sensor terminal block. See the Installation section of this insert for all wiring procedures related to the transmitter.

Ampliﬁer

The ampliﬁer converts the electrical output from the oxygen sensor to a 4 to 20 mA signal (that is proportional to the detection range) and transmits the signal to the Pioneer. The ampliﬁer includes the ampliﬁer type selector, detector terminal strip, interconnect terminal strip, span potentiometer, zero potentiometer, and test points (see Figure 1.)

Ampliﬁer type selector

The ampliﬁer type selector is near the top left corner of the ampliﬁer. It is above the detector terminal strip and to the left of the span potentiometer.

The ampliﬁer included with the oxygen transmitter is designed for use with RKI’s oxygen and toxic gas transmitters. The ampliﬁer type selector determines for which transmitter the ampliﬁer is intended. For oxygen transmitters, a jumper block is installed over the

OXY selector (see Figure 1.)

Detector terminal strip

The detector terminal strip is the four-point terminal strip on the left side of the ampliﬁer. Use the detector terminal strip to connect the oxygen detector to the ampliﬁer.

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

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

Interconnect terminal strip

The interconnect terminal strip is the four-point terminal strip on the right side of the ampliﬁer. Use the interconnect terminal strip to connect the ampliﬁer to the Pioneer.

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 3

Span potentiometer

The span potentiometer is near the top of the ampliﬁer. Of the three potentiometers, the span potentiometer is farthest to the left. Use the span potentiometer to adjust the transmitter’s response output during the start-up and calibration procedures.

Zero potentiometer

The zero potentiometer is to the right of the span potentiometer. Use the zero potentiometer to adjust the transmitter’s oxygen-free output during the calibration procedure.

CAUTION: The third potentiometer is factory-set. Do not adjust it.

Test points

The test points (labeled TP- and TP+ ) are directly above and below the interconnect terminal strip. The test points produce a 100 to 500 mV output that is proportional 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.

Ampliﬁer junction box

Use the ampliﬁer junction box to install the ampliﬁer at a mounting site that is remote from the Pioneer. The junction box also protects the ampliﬁer and wiring connections made to the ampliﬁer. Use the two 3/4 in. conduit hubs to connect the detector junction box to the ampliﬁer junction box (bottom hub) and connect wiring from the ampliﬁer to the Pioneer (top hub).

NOTE: The ampliﬁer is factory-mounted to the ampliﬁer junction box.

Use the ampliﬁer junction box’s two mounting holes to mount the oxygen 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.

Oxygen Transmitter • 4 Pioneer Operator’s Manual (PRELIMINARY)

Installation

This section describes procedures to mount the oxygen transmitter in the monitoring environment and wire the transmitter to the Pioneer Gas Monitor.

Mounting the Oxygen 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 that is at normal breathing level.

CAUTION: Mount the oxygen transmitter with the ampliﬁer junction box above the detector

junction box (see Figure 2.)

2. At the monitoring site, use 1/4 in. screws through the two mounting holes on the left side of the ampliﬁer junction box to secure the e junction box to the vertical mounting surface (see Figure 2.)

5.25 in.

5.9 in.

10.5 in.

5.0 in.

Note: The junction box is 4.63 in. deep.

Figure 2: Mounting the Oxygen Transmitter

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 5

Wiring the Oxygen Transmitter to the Pioneer

WARNING: Always verify that the Pioneer’s power switch is in the OFF position

before you make wiring connections.

1. Place the Pioneer’s power switch in the OFF position.

2. Loosen the two securing screws from the detector junction box cover, then remove the cover.

3. Unscrew and remove the ampliﬁer junction box cover.

4. In the detector junction box, verify that the leads from the sensor connector are wired to the (2-point) sensor terminal block.

5. In the ampliﬁer junction box, verify that the wiring from the opposite side of the (2-point) sensor terminal block is wired to the ampliﬁer’s detector terminal strip.

If necessary, connect the sensor terminal block and detector terminal strip as shown in Figure 3.

6. Verify that the jumper block is installed over the OXY selector of the ampliﬁer type selector as shown in Figure 3.

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

8. Connect the two wires to the interconnect terminal strip as follows (see Figure 3.)

• Connect the positive wire to the terminal labeled 24V + .

• Connect the feedback wire to the terminal labeled 4/20 FB .

CAUTION: Leave the ground wire insulated and disconnected at the transmitter. You will

connect the opposite end of the cable’s ground wire at the Pioneer.

9. Secure the detector junction box cover to the junction box with the two screws you removed in step 2.

10. Secure the ampliﬁer junction box cover to the junction box.

11. Route the cable or wires leading from the oxygen transmitter through one of the conduit hubs on the bottom of the Pioneer 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 Pioneer.

Oxygen Transmitter • 6 Pioneer Operator’s Manual (PRELIMINARY)

12. Connect the wires to the detector terminal strip of the applicable analyzer card as shown in Figure 3. The detector terminal strip is the 7-point terminal strip (terminals 1 through 7) on the card.

Oxygen Amplifier

TOXIC

OXY

white

TOXIC

OXY

—

BATT

+ FB

24V4/20

7 Gnd 6 24 V 5 4-20

4 RED 3 WHT

green

2 GRN

1 BLK

Oxygen

Sensor

Detector Terminal Strip

(on Pioneer Analyzer Card)

Oxygen Detector

Figure 3: Wiring the Oxygen Transmitter to the Pioneer Gas Monitor

13. At the Pioneer, connect the cable’s ground wire to an available chassis ground. The grounding screw on each conduit hub is an example of a chassis ground.

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 7

Start Up

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

Introducing Incoming Power

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

2. Verify that the power wiring is correct and secure (see Chapter 3, Installation and Start Up).

3. Turn on or plug in the incoming power at the power source end, then place the Pioneer’s power switch in the ON position.

4. Verify that the main PILOT light is on and the pilot light for each analyzer card is ﬂashing.

Setting the Normal Signal

CAUTION: If you suspect the monitoring environment is not of normal oxygen content (20.9%),

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

1. Verify that the transmitter is in a fresh air environment (environment known to be of normal oxygen content).

2. Unscrew and remove the ampliﬁer 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 negative lead into the test point labeled TP- .

5. Verify a voltmeter reading of 434.4 mV (±2 mV).

6. If necessary, use a ﬂat-blade screwdriver to adjust the span potentiometer until the voltmeter reading is 434.4 mV (±2 mV).

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

Oxygen Transmitter • 8 Pioneer Operator’s Manual (PRELIMINARY)

Channel Setup Program

This section describes the Pioneer’s Channel Setup program for the oxygen transmitter. You can display and change the following channel settings with the Channel Setup program.

• Channel Status

• Target Gas, Unit of Measure, and Fullscale Setting

• Channel Type

• Relay 3 Assignment

• Alarm Setpoints and Alarm Type (rising or falling)

NOTE: Channels that are included with the original shipment of the Pioneer are setup at

the factory. If you are adding a channel to an existing Pioneer, you need to establish the channel settings in this program.

Navigating through the Channel Setup Program

Table 2: Program Button Functions for the Channel Setup Program

Button Function

ESCAPE • Moves you backward through the program.

• Cancels changes made to the program

settings.

UP/YES • Updates the setting that is displayed on the

display screen.

• Saves changes made to the program settings.

DOWN/NO • Updates the setting that is displayed on the

display screen.

• Enters the program (with the ENTER button).

• Saves changes made to the program settings.

ENTER • Moves you forward through the program.

• Enters the program (with the DOWN/NO

button).

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 9

Running the Channel Setup Program

This section describes how to enter the program, display and change program settings, and save or cancel changes to the program settings.

Entering the channel setup program

1. Open the housing door, and locate the program buttons to the right of the display screen.

2. Press the ENTER and DOWN/NO buttons simultaneously three times. The Channel Setup program screen appears.

ersi

V Cha ESCA A

NYTO

on X.XX

ne tSen

pul Abor t REK

Nex t

NOTE: Once you enter the Channel Setup program, the status lights, buzzer, and relays

are disabled until you exit the program.

3. Press the UP/YES, DOWN/NO, or ENTER button to continue. The program asks if you want to setup Channel 1.

C ESCAE t UP/D

NTER

NOTE: The screens illustrated in this section are examples and describe the Channel

Setup program for Channel 1.

ann

P N

angeC

tpu

Now

ann

Oxygen Transmitter • 10 Pioneer Operator’s Manual (PRELIMINARY)

Channel status screen

This screen indicates the status of Channel 1. For installed channels the default setting is

ACTIVE/ONLINE . For empty channels, the default setting is NO SENSOR/AMP . The

third setting, SILENCED/OFFLINE , displays the gas reading as XXXX; and the buzzer, status lights, and relays are disabled for the channel.

hanne l

C ACTIVE/

1 N

LINE

• To accept the channel status setting and continue the program, press the ENTER button.

The program displays the Fullscale Reading, Unit of Measure, and Target Gas screen.

• To update the channel status setting:

1. Use the UP/YES and DOWN/NO buttons to change the setting.

2. Press the ENTER button to accept the new setting and continue the program. The program displays the Fullscale Reading, Unit of Measure, and Target Gas screen.

NOTE: If you select a channel status of NO SENSOR/AMP , the program continues with

the next channel.

Fullscale reading, unit of measure, and target gas screen

This screen indicates the fullscale reading, unit of measure, and target gas for Channel 1. The default settings for the oxygen channel are 25.0 (fullscale reading), %VOL (unit of measure), and OXY (target gas).

25 0 %VO

XY.

• To accept the settings and continue the program, press the ENTER button three times. The program displays the Channel Type screen.

• To update the target gas, unit of measure, and/or fullscale reading setting:

1. Use the ENTER and ESCAPE buttons to select the setting you want to change.

(The setting ﬂashes when it is selected.)

2. Use the UP/YES and DOWN/NO buttons to change the setting.

3. Press the ENTER button until the program displays the Channel Type screen.

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 11

Channel type screen

This screen indicates the channel type for Channel 1. The default setting for the channel type (input) setting for the oxygen transmitter is 4-20 Remote .

INPUT:

0Remte

4-2

• To accept the setting and continue the program, press the ENTER button. The program displays the Relay 3 Assignment screen.

• To update the setting:

1. Use the UP/YES or DOWN/NO button to change the setting.

2. Press the ENTER button to accept the new setting and continue the program. The program displays the Relay 3 Assignment screen.

Relay 3 assignment screen

This screen indicates the assignment of the alarm 3 relay for Channel 1. If you select

Alarm 3 , then the alarm 3 relay activates if Channel 1 goes into an alarm 3 condition.

If you select Fail Alarm , then the alarm 3 relay de-energizes if Channel 1 goes into a fail condition.

NOTE: If you assign the alarm 3 relay as the channel’s fail relay, the status light and

buzzer still indicate visual and audible alarms for an alarm 3 condition.

hanne l

C Rela

Alarm

igned

• To accept the relay 3 assignment setting and continue the program, press the ENTER button.

The program displays the Fail Setpoint screen.

• To update the relay 3 assignment setting:

1. Use the UP/YES or DOWN/NO button to change the setting.

2. Press the ENTER button to accept the new setting and continue the program. The program displays the Fail Setpoint screen.

Oxygen Transmitter • 12 Pioneer Operator’s Manual (PRELIMINARY)

Fail setpoint screen

The default setting for the fail setpoint for the oxygen channel is -2.0 . The default setting for the alarm type is FALL .

anne

0%VO

ail Alarm

AFLL

• To accept the settings and continue the program, press the ENTER button two times. The program displays the Alarm 1 Setpoint screen.

• To update the fail setpoint setting:

1. Use the UP/YES and DOWN/NO buttons to change the fail setpoint setting.

2. Press the ENTER button two times to accept the new setting and continue the

program.

The program displays the Alarm 1 Setpoint screen.

• To update the alarm type setting:

1. Press the ENTER button to select the alarm type setting. (The setting ﬂashes when

it is selected.)

2. Use the UP/YES or DOWN/NO button to change the setting.

3. Press the ENTER button to accept the new setting and continue the program. The program displays the Alarm 1 Setpoint screen.

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 13

Alarm 1 setpoint screen

This screen indicates the setpoint and alarm type for Alarm 1. The default setting for the alarm 1 setpoint for the oxygen channel is 19.5 . The default setting for the alarm type is

FALL .

anne l 1 A larm

5%VO

FALL

• To accept the settings and continue the program, press the ENTER button two times. The program displays the Alarm 2 Setpoint screen.

• To update the alarm 1 setpoint:

1. Use the UP/YES and DOWN/NO buttons to change the setpoint.

2. Press the ENTER button two times to accept the new setting and continue the

program.

The program displays the Alarm 2 Setpoint screen.

• To update the alarm type setting:

1. Press the ENTER button to select the alarm type setting. (The setting ﬂashes when

it is selected.)

2. Use the UP/YES or DOWN/NO button to change the setting.

3. Press the ENTER button to accept the new setting and continue the program. The program displays the Alarm 2 Setpoint screen.

Alarm 2 setpoint screen

This screen indicates the setpoint and alarm type for Alarm 2. The default setting for the alarm 2 setpoint for the oxygen channel is 17.0 . The default setting for the alarm type is

FALL .

anne l 1 A larm

70%VO

A2F

• To accept the settings and continue the program, press the ENTER button two times. The program displays the Alarm 3 Setpoint screen.

• To update the alarm 2 setpoint:

1. Use the UP/YES and DOWN/NO buttons to change the setpoint.

2. Press the ENTER button two times to accept the new setting and continue the

program.

The program displays the Alarm 3 Setpoint screen.

• To update the alarm type setting:

1. Press the ENTER button to select the alarm type setting. (The setting ﬂashes when

it is selected.)

2. Use the UP/YES or DOWN/NO button to change the setting.

3. Press the ENTER button to accept the new setting and continue the program. The program displays the Alarm 3 Setpoint screen.

Oxygen Transmitter • 14 Pioneer Operator’s Manual (PRELIMINARY)

Alarm 3 setpoint screen

This screen indicates the setpoint and alarm type for Alarm 3. The default setting for the alarm 3 setpoint for the oxygen channel is 23.5 . The default setting for the alarm type is

RISE .

anne l 1 A larm

35%VO

RISE

• To accept the settings and continue the program, press the ENTER button two times. The program begins channel setup for Channel 2.

• To update the alarm 3 setpoint:

1. Use the UP/YES and DOWN/NO buttons to change the setpoint.

2. Press the ENTER button two times to accept the new setting and continue the

program.

The program begins channel setup for Channel 2.

• To update the alarm type setting:

1. Press the ENTER button to select the alarm type setting. (The setting ﬂashes when

it is selected.)

2. Use the UP/YES or DOWN/NO button to change the setting.

3. Press the ENTER button to accept the new setting and continue the program. The program begins channel setup for Channel 2.

NOTE: To exit the Channel Setup program, press the ESCAPE button. The Channel

Setup Exit screen displays.

Channel setup exit screen

This screen saves or cancels any changes you made in the Channel Setup program.

Abor t Se

Save & Ex i

Nex t

APE

UP/DOWN

ENTER

• To save changes and exit the program, press the UP/YES or DOWN/NO button.

The program displays a conﬁrmation message, then the normal screen appears. The Pioneer is in normal operation.

• To cancel changes and exit the program, press the ESCAPE button.

The program displays a conﬁrmation message, then the normal screen appears. The Pioneer is in normal operation.

• To setup another channel , press the ENTER button.

The program asks if you want to setup the next channel. Press the ENTER button to continue.

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 15

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 oxygen transmitter. It includes daily, monthly, and quarterly procedures.

Daily

1. Verify that the pilot light on the applicable analyzer card is ﬂashing. If the pilot light is

NOTE: If the Pioneer’s main PILOT light is not on, see the Troubleshooting guide in

not ﬂashing, see the following troubleshooting guide in this insert.

Chapter 5, Maintenance.

2. Verify a display reading of 20.9 %VOL. Investigate signiﬁcant changes in the display reading.

Monthly

This procedure describes a test to verify that the oxygen transmitter responds properly to oxygen deﬁciency.

Preparing for the response test

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

2. 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 lead into the test point labeled

3. At the Pioneer, verify that the display reading(s) for the channel(s) you plan to test is

20.9. If the display reading(s) is not 20.9, set the fresh air reading of the applicable

transmitter(s) as described in the Start Up section of this insert, then continue this procedure.

Entering the Calibrate program

1. Open the Pioneer’s housing door, and locate the program buttons to the right of the display screen.

2. Press the ENTER and UP/YES button simultaneously three times. The Calibrate program screen appears.

TP-

TP+

; plug the negative

ersi

V Cal ESCA A

NYTO

NOTE:

Oxygen Transmitter • 16 Pioneer Operator’s Manual (PRELIMINARY)

Once you enter the Calibrate program, the status lights, buzzer, and relays are disabled until you exit the Calibrate program.

The Pioneer automatically exits the Calibrate program if you do not exit the program before the calibration time-out setting expires. You can display and change the settings in the Instrument Setup program (see Chapter, Operation.)

on X.XX

irateb

Abort REK

Nex t

3. Press the UP/YES, DOWN/NO, or ENTER button to continue. The Select screen appears. The ﬁrst line (channel 1) is ﬂashing.

Selecte

NOTE:

The example used in this procedure describes a response test for Channels 3 and 4.

4. Press the DOWN/NO button two times. The third line (channel 3) is ﬂashing.

5. Press the ENTER button to “select” Channel 3, then press the DOWN/NO button.

6. Press the ENTER button to “select” Channel 4, then press the DOWN/NO button.

NOTE:

The description for Channels 3 and 4 changes to

4-20 Monitor

when you “select”

Channels 3 and 4.

The Channels Selected screen appears.

uhav

these Cha

eSelecte

nels:

34,

ENTER Nex

7. Verify that you selected the correct channel(s), then press the ENTER button to continue.

The Choose Calibration screen appears.

Choose Ca

Oxygen

Zero

ENTERNex

NOTE

: If one or more of the channels you selected on the Select screen is set up for a

ibr

ProceeSpan Proceed

target gas other than oxygen, then the Choose Calibration screen appears as follows.

Choose Ca

(

Oxygen OSpan

Nex

ENT

ibr

neg

Spa

Zero

)

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 17

8. Verify that the

Oxygen Zero Proceed

line is ﬂashing [or

Span (Oxygen Zero)

applicable], then press the ENTER button to continue. If the Oxygen Zero Proceed line is not ﬂashing, press the DOWN/NO button, then press the ENTER button.

The Calibration screen appears.

(

NottSe lec t ed

Se lec t edoN

0.0 OXY

0.0OXY

) )(

9. Press the ENTER button. The Apply Gas screen appears.

APE

ENTER

Pr vi u

ly G

s as

10. Press the ENTER button. The Span screen appears.

C C C C

XXX XXX

20.9

9.02

Spa

pply

NTER

Performing the response test

1. Exhale into the diffusion port in the oxygen detector’s junction box cover.

NOTE: Once you begin exhaling into the diffusion port, the Span screen “freezes” and

displays each “selected” channel’s lowest reading. This feature enables you to verify the readings at the Pioneer in addition to the “local” test at the transmitter.

2. Stop exhaling into the diffusion port, then verify that the readings on the voltmeter decreased from the normal reading (434.4 mV).

NOTE: If the reading(s) does not decrease, calibrate the affected transmitter(s) as

described in the Calibration section of this insert. If the oxygen reading(s) is below the alarm 1 setpoint when you return to the

normal screen, the Pioneer will initiate the appropriate alarm condition. You can view the reading(s) of the “selected” channels on the Fresh Air screen.

T o display the Fr esh Air screen, press the ESCAPE button, next pr ess the UP/YES button, then press the ENTER button.

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

4. Press the ESCAPE button until the Save screen appears.

Abor t Se

Save & Ex i

Nex t

APE

UP/DOWN

ENTER

Oxygen Transmitter • 18 Pioneer Operator’s Manual (PRELIMINARY)

5. Press the ESCAPE button. A conﬁrmation message displays, then the normal screen appears.

TRUM N

NS NOT PREV

UVA

UAVEDS

SING

NOTE: The Pioneer does not save calibration values for remote transmitters. When

calibrating the transmitter, you perform calibration at the transmitter; therefore, it is not necessary to save calibration values at the Pioneer.

The purpose of entering the Calibrate program when performing this response test is to disable the status lights, buzzer, and relays and so you can view the response reading(s) on the Span screen.

Quarterly

Calibrate the oxygen transmitter as described in the Calibration section of this insert.

Troubleshooting

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

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

Troubleshooting guide in Chapter 5, Maintenance, for problems you may encounter with the Pioneer Gas Monitor.

Fail condition

Symptoms

• The FAIL light is on.

• The buzzer is sounding a steady tone.

• The fail relay is de-energized.

• The display reading is ﬂashing.

Probable causes

• The analyzer card is disconnected or misconnected.

• The transmitter wiring is disconnected or misconnected.

• The transmitter is malfunctioning.

Recommended action

1. Verify that the analyzer card is installed correctly and that the pilot light on the analyzer card is ﬂashing. The components of the analyzer card face left when the card is installed correctly.

2. Verify that the transmitter wiring is correct and secure. The Installation section of this insert describes transmitter wiring connections.

3. Calibrate the transmitter as described in the Calibration section of this insert.

4. If the fail condition continues, replace the detector as described later in this section.

5. If the fail condition continues, contact RKI Instruments, Inc., for further instruction.

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 19

Slow or no response/difﬁcult or unable to calibrate

Symptoms

• The transmitter responds slowly or does not respond during the monthly response test.

• Unable to accurately set the fresh air or zero reading during the calibration pr ocedur e.

• The transmitter requires frequent calibration.

NOTE: Under “normal” circumstances, the transmitter requires calibration once every

three months. Some applications may require a more frequent calibration schedule.

Probable causes

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

• The detector junction box’s diffusion port is obstructed.

• The transmitter is malfunctioning.

Recommended action

1. Verify that the calibration cylinder contains an adequate supply of a fresh test sample.

2. Verify that the detector junction box’s diffusion port is not obstructed.

3. If the calibration/response difﬁculties continue, replace the detector as described later in this section.

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

No display reading

Symptoms

• The transmitter is installed, but the display screen is blank for that channel.

NOTE: If the display screen is blank for all channels, see the troubleshooting guide in

Chapter 5, Maintenance.

Probable causes

• The channel status setting is set at NO SENSOR/AMP.

Recommended action

1. Enter the Channel Setup program, and change the channel status setting to ACTIVE/ ONLINE or SILENCED/OFFLINE.

2. If the display reading difﬁculties continue, contact RKI Instruments, Inc., for further instruction.

Oxygen Transmitter • 20 Pioneer Operator’s Manual (PRELIMINARY)

Replacing Components of the Oxygen Transmitter

This section includes procedure to replace the oxygen sensor, ampliﬁer, and sensor backup battery.

Replacing the oxygen sensor

1. Place the Pioneer’s power switch in the OFF position.

2. Loosen the two securing screws from the detector junction box cover, then remove the cover.

The sensor is mounted to the back of the junction box cover. A retaining strip secures the sensor to the cover. The retaining strip is secured by two screws in standoffs. One end of the strip has a slot cutout.

3. Loosen one of the screws that secures the retaining strip (cutout end), then rotate the retaining strip so it no longer covers the sensor.

4. Unplug the sensor socket from the male connector, them remove the sensor.

5. Place the replacement sensor in the same position as the original sensor, then rotate the securing strip over the sensor. Tighten the screw you removed in step 3 to secure the sensor to the junction box cover.

6. Plug the socket of the replacement sensor into the male connector.

7. Place the Pioneer’s power switch in the ON position.

8. Secure the detector junction box cover to the junction box with the two screws you removed in step 2.

9. Calibrate the replacement detector as described in the Calibration section of this insert.

Replacing the ampliﬁer

1. Place the Pioneer’s power switch in the OFF position.

2. Remove the ampliﬁer junction box cover.

3. Disconnect the wiring from the detector terminal strip.

NOTE: Leave the opposite end of the wiring connected in the detector junction box.

4. Disconnect the wiring from terminals 4/20 FB and 24V + of the interconnect terminal strip.

NOTE: Leave the opposite end of the wiring connected at the Pioneer.

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

6. Remove the ampliﬁer.

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

8. Use the two screws you removed in step 5 to secure the ampliﬁer to the junction box.

9. Verify that the jumper block is installed over the OXY selector of the ampliﬁer type selector as shown in Figure 3, Wiring the Oxygen Transmitter to the Pioneer Gas Monitor.

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 21

10. Reconnect the wiring from the Pioneer to the interconnect terminal strip as shown in Table 3 and Figure 3, Wiring the Oxygen Transmitter to the Pioneer Gas Monitor.

Table 3: Reconnecting the Oxygen Ampliﬁer to the Pioneer Gas Monitor

Ampliﬁer

Interconnect Terminal Strip

Pioneer Analyzer Card

4/20 FB 4-20 (Terminal 5)

24V + 24 V (Terminal 6)

11. Reconnect the wiring from the (2-point) sensor terminal block in the detector junction box to the ampliﬁer’s detector terminal strip as shown in Table 4 and Figure 3, Wiring the Oxygen Transmitter to the Pioneer Gas Monitor.

Table 4: Reconnecting the Oxygen Detector to the Ampliﬁer

Sensor

Terminal Block

Interconnect Terminal Strip

Ampliﬁer

+ (white) OXY W

— (green) OXY G

12. Place the Pioneer’s power switch in the ON position.

13. Calibrate the oxygen transmitter as described in the Calibration section of this insert.

Oxygen Transmitter • 22 Pioneer Operator’s Manual (PRELIMINARY)

Calibration

This section describes how to calibrate the oxygen transmitter. It includes procedures to set the fresh air reading, assemble the calibration kit, enter the Calibrate program, set the zero reading, and return to normal operation.

WARNING: The Pioneer is not an active gas monitoring device during the calibration

procedure.

Setting the Fresh Air Reading

1. Verify that the oxygen transmitter is in a fresh air environment (environment known to be of normal oxygen content).

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

3. 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-.

4. Verify a voltmeter reading of 434.4 mV (±2 mV).

5. If necessary, use a ﬂat-blade screwdriver to adjust the span potentiometer until the voltmeter reading is 434.4 mV (±2 mV).

Assembling the Calibration Kit

1. Connect one end of the sample tubing to the regulator.

2. Connect the opposite end of the sample tubing to the calibration cup.

NOTE: Do not screw the regulator into the calibration cylinder at this time.

Entering the Calibrate Program

1. Open the housing door of the Pioneer, and locate the program buttons to the right of the display screen.

2. Press the ENTER and UP/YES buttons simultaneously three times. The Calibrate program screen appears.

ersi

V Cal ESCA A

NYTO

NOTE: Once you enter the Calibrate program, the status lights, buzzer, and relays are

disabled until you exit the Calibrate program. The Pioneer automatically exits the Calibrate program if you do not exit the

program before the calibration time-out setting expires. You can display and change the settings in the Instrument Setup program (see Chapter, Operation.)

on X.XX

irateb

Abort

REK

Nex t

Pioneer Operator’s Manual (PRELIMINARY) Oxygen Transmitter • 23

3. Press the UP/YES, DOWN/NO, or ENTER button to continue. The Select screen appears. The ﬁrst line (channel 1) is ﬂashing.

C C C C

H1 H H H

Selecte

NOTE: The example used in this procedure describes calibration for Channels

1, 2, and 3.

4. Press the ENTER button to “select” Channel 1, then press the DOWN/NO button. The second line (channel 2) is ﬂashing.

5. Repeat step 4 to “select” Channels 2 and 3.

NOTE: The description for Channels 1, 2, and 3 changes to 4-20 Monitor when you

“select” Channels 1, 2, and 3.

6. Press the DOWN/NO button. The Channels Selected screen appears.

uhav

these Cha

,2,

ENTER Nex

eSelecte

nels:

7. Verify that you selected the correct channel(s), then press the ENTER button to continue.

The Choose Calibration screen appears.

Choose Ca Oxygen

Zero

ENTERNex

ibr

ProceeSpan Proceed

NOTE: If one or more of the channels you selected on the Select screen is set up for a

target gas other than oxygen, then the Choose Calibration screen appears as follows.

Choose Ca

(

Oxygen OSpan

Nex

ENT

ibr

neg

Spa

Zero

)

Oxygen Transmitter • 24 Pioneer Operator’s Manual (PRELIMINARY)

RKI Instruments Pioneer 4W User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual