RKI INSTRUMENTS 65-2422RK-05 Hydrogen Sulfide Transmitter Instruction Manual

**RKI INSTRUMENTS 65-2422RK-05 Hydrogen Sulfide Transmitter Instruction Manual

**

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

Periodic calibration and maintenance of the detector is essential for proper operation and correct readings. Please calibrate and maintain this detector regularly! Frequency of calibration depends upon the type of use you have and the sensor types. Typical calibration frequencies for most applications are between 3 and 6 months, but can be required more often or less often based on your usage.

Product Warranty

RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free from defects in materials, workmanship, and performance for a period of one year from date of shipment from RKI Instruments, Inc. Any parts found defective within that period will be repaired or replaced, at our option, free of charge. This warranty does not apply to those items which by their nature are subject to deterioration or consumption in normal service, and which must be cleaned, repaired, or replaced on a routine basis. Examples of such items are

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

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or
repair procedures not in accordance with the operator’s manual. This warranty indicates the full extent of our liability, and we are not responsible for removal or replacement costs, local repair costs, transportation costs, or contingent expenses incurred without our prior approval.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES

AND REPRESENTATIONS, EXPRESSED OR IMPLIED, AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF RKI INSTRUMENTS, INC. INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS, INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL LOSS  OR DAMAGE OF ANY KIND CONNECTED WITH THE USE OF ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR OPERATE PROPERLY

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

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

Overview

This manual describes the hydrogen sulfide (H2S) transmitter. This manual also describes how to install, start up, maintain, and calibrate the transmitter. A parts list at the end of this manual lists replacement parts and accessories for the H2S transmitter

Specifications

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

Table 1 lists specifications for the H2S transmitter

Table 1: Specifications

equipment or parts of equipment, telecommunication, electronic, etc., with smaller transient overvoltages than Installation Category (Overvoltage Category) II (ref. IEC 664).
Input Voltage| 11 VDC – 30 VDC
Sampling Method| Diffusion
Signal Output| 4 to 20 mA
Detection Range| 0 to 100 PPM (parts per million)
Accuracy| ± 5% of reading or ± 2 ppm H2S (whichever is greater)
H 2S Detector Signal Output| 0.3 mA at 0 ppm H2S nominal2.5 mA at 100 ppm H2S nominal
Response Time| 90% in 30 seconds
Operating Temperature| -40°F to 104°F (-40°C to 40°C)

NOTE: The following symbol on the detector label is a caution to the user to refer to this documentation for installation and operation instructions:

WARNING: When using the 65-2422RK-05, you must follow the instructions and warnings in this manual to assure proper and safe operation of the 65-2422RK-05 and to minimize the risk of personal injury. Be sure to maintain and periodically calibrate the 65-2422RK-05 as described in this manual.

Description

This section describes the components of the H2S transmitter. The transmitter consists of the H2S detector, amplifier, and junction box.

Figure 1: H2S Transmitter Component Location

H2S Detector
The H2S detector includes the detector housing body, detector housing cap, cap gasket, rubber boot, spacer, and the plug-in H2S sensor.

Figure 2: H2S Detector Component Location

Detector Housing Body

The detector housing body protects the electronic components within the housing. Use the mounting threads at the top of the housing to screw the H2S detector into the 3/4 NPT hub on the bottom of the junction box. Two wires extend from the top of the detector housing body.

Use these wires to connect the H2S detector to the amplifier. One of the wires is red and one of the wires is black.

The housing includes a four-socket pattern. This socket pattern accepts the sensor’s four pins to secure the sensor within the detector housing. A pre- amplifier, located between the sockets and two interconnect wires, conditions the sensor’s signal before the signal reaches the
controller.

Housing Cap & Cap Gasket

The housing cap screws onto the detector housing. It retains the plug-in sensor and protects it from damage. The housing cap also includes a flame arrestor which contains any sparks that may occur within the detector and a flame arrestor guard which protects the flame arrestor from damage. Unscrew the detector cap to access the plug-in sensor for maintenance or replacement. A cap gasket seals the interface between the housing and cap.

Rubber Boot and Spacer

A rubber boot and spacer are installed between the detector housing cap and the sensor. They help ensure that the detector remains plugged into the detector housing body

Plug-In H2S Sensor

The sensor is secured within the sensor housing by the four pins. Through a series of chemical and electrical reactions, the sensor produces an electrical output that is proportional to the detector range of the transmitter.

Amplifier

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

Amplifier Type Selector

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

The amplifier included with the H2S transmitter is designed for use with RKI’s toxic gas and oxygen transmitters. The amplifier type selector determines for which transmitter the amplifier is intended. For H2S transmitters, a jumper block is installed over the TOXIC selector (see Figure 1).

Detector Terminal Strip

The detector terminal strip is the four-point terminal strip near the bottom of the amplifier. Use the detector terminal strip to connect the H2S detector to the amplifier.

NOTE: The H2S detector is factory-wired to the amplifier. See the Installation section of this manual for all wiring procedures related to the transmitter.

Interconnect Terminal Strip

The interconnect terminal strip is the four-point terminal strip near the top of the amplifier. Use the interconnect terminal strip to connect the amplifier to a controller.

Span Pot

The span pot is on the left side of the amplifier. Of the three potentiometers, the span pot is bottom most. Use the span pot to adjust the transmitter’s response output during the
calibration procedure.

Zero Pot

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

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

Test Points

The test points (labeled TP- and TP+) are on the left and right side 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.

Junction Box

Use the junction box to install the H2S transmitter at a mounting site that is remote from the controller. The junction box also protects the amplifier and wiring connections made to the amplifier. Use the two 3/4 NPT conduit hubs to mount the detector to the junction box (bottom hub) and connect wiring from the amplifier to the controller (top hub).

NOTE: The H2S detector and amplifier are factory-mounted to the junction box.

Use the junction box’s two mounting holes to mount the H2S 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

Installation

This section describes procedures to mount the H2S transmitter in the monitoring environment and wire the transmitter to a controller.

Mounting the H2S 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.
     NOTE: If your application does not require a specific mounting site, mount the transmitter at approximately breathing level.
     
     Figure 3: Mounting the H2S Transmitter
     If the H2S detector is mounted to the junction box, skip to step 5. If not, continue with step 2.
     NOTE: The H2S detector is normally provided with a Killark HKB junction box and an HFC lid rated explosion proof for Class I, Groups B, C, and D. This combination is shown in Figure 2 above. Any junction box with an internal volume less than or equal to 69 cubic inches and rated explosion proof for ClassI, Groups B, C, and D may be used.

2. Remove the junction box cover.

3. Guide the two wires that extend from the top of the H2S detector through the bottom conduit hub of the junction box.

4. Screw the H2S detector into the bottom conduit hub of the junction box.

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

CAUTION: Mount the H2S transmitter with the detector facing down (see Figure 2)

Wiring the H2S Transmitter to a Controller

WARNING: Always verify that the power source is OFF before you make wiring connections.

1. Turn off the controller.

2. Turn off or unplug incoming power at the controller.

3. Remove the junction box cover.

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

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

6. Guide a two-conductor, shielded cable or two wires in conduit through the top conduit hub of the junction box.
   WARNING: To maintain the explosion proof classification of the H2S detector/junction box combination, a conduit seal must be used within 18 inches of the junction box
   conduit hub used for wiring to the controller.

7. 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: If using shielded cable, leave the drain wire insulated and disconnected at the transmitter. You will connect the opposite end of the cable’s drain wire at the controller.

8. Secure the junction box cover to the junction box.

9. Route the cable or wires leading from the H2S transmitter through one of the conduit hubs at the controller housing.
   CAUTION: Do not route power and transmitter wiring through the same conduit hub. The power cable may disrupt the transmission of the transmitter signal to the controller

10. Connect the wires to the to the applicable controller transmitter terminal strip as shown in Figure 3
    
    Figure 4: Wiring the H2S Transmitter to a Controller

11. If shielded cable is used, connect the cable’s drain wire to an available chassis (earth) ground at the controller. RKI controllers typically have a ground stud that can be used to ground the cable’s drain wire.

Start Up

This section describes procedures to start up the H2S transmitter and place the transmitter into normal operation. Introducing Incoming Power

1. Complete the installation procedures described earlier in this manual.
2. Verify that the power wiring to the controller is correct and secure. Refer to the controller instruction manual.
3. Turn on or plug in the incoming power at the power source end, then turn on the controller.
4. Verify that the controller is on and operating properly. Refer to the controller instruction manual.

CAUTION: Allow the transmitter to warm up for 5 minutes before you continue with the next section, “Setting the Zero Signal”. Setting the Zero Signal

WARNING: Do not remove the sensor cap or junction box cover while the circuits are energized unless the area is determined to be non-hazardous. Keep the sensor cap and junction box cover tightly closed during operation.

NOTE: If you can verify that the detector is in a fresh air environment (environment known to be of normal oxygen content and free of toxic and combustible gases), it is not necessary to apply zero air when verifying or setting the fresh air reading.

The procedure below describes applying zero emission air, usually called zero air, using a
calibration kit that includes a calibration cup, calibration gas, sample tubing, and a fixed flow regulator with an on/off knob. RKI Instruments, Inc. recommends using a 0.5 LPM (liters per minute) fixed flow regulator.

1. Unscrew and remove the junction box cover from the junction box.
2. Set a voltmeter to measure in the millivolt (mV) range.
3. 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. Screw the calibration cup onto the bottom of the detector.
5. Screw the regulator into the zero air calibration cylinder.
6. Use the sample tubing to connect the regulator to the calibration cup.
7. Turn the regulator’s on/off knob counterclockwise to open it. Gas will begin to flow.
8. Allow the gas to flow for 2 minutes.
9. Verify a voltmeter reading of 100 mV (±2 mV).
10.  If necessary, use a flat-blade screwdriver to adjust the span pot until the voltmeter reading is 100 mV (±2 mV).
11. Turn the regulator’s on/off knob clockwise to close it.
12. Unscrew the calibration cup from the detector.
13.  Unscrew the regulator from the zero air calibration cylinder. For convenience, leave the sample tubing connected to the regulator and the calibration cup.
14. Store the components of the calibration kit in a safe and convenient place.
15. Remove the voltmeter leads from the test points.
16. Secure the junction box cover to the junction box.

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 H2S transmitter. It includes daily and quarterly procedures.

Daily
Verify a display reading of 0 PPM H2S at the controller. Investigate significant changes in the display reading.

Quarterly
Calibrate the H2S transmitter as described in the Calibration section of this manual.

Troubleshooting
The troubleshooting guide describes symptoms, probable causes, and recommended action for problems you may encounter with the H2S transmitter.

NOTE: This troubleshooting guide describes transmitter problems only. See the controller instruction manual for problems you may encounter with the controller.

Fail Condition
Symptoms

• The controller indicates a fail condition. Probable causes
• The transmitter wiring is disconnected or misconnected.
• The transmitter’s zero reading is low enough to cause a fail condition.
• The transmitter is malfunctioning

Recommended action

• Verify that the transmitter wiring is correct and secure.
• Calibrate the transmitter.
• If the fail condition continues, replace the H2S sensor.
• If the fail condition continues, contact RKI for further instruction.

Slow or No Response/Difficult or Unable to Calibrate
Symptoms

• 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 H2S sensor as described later in this section.
3. If the calibration/response difficulties continue, contact RKI Instruments, Inc. for further instruction.

Replacing Components of the H2S Transmitter
This section includes procedure to replace the H2S sensor and amplifier. A procedure to replace the entire detector assembly is at the end of this section. In most cases, it is not necessary to replace the entire detector assembly.

Replacing the Sensor

CAUTION: The sensor contains electrolyte which is a dilute acid. Do not disassemble the sensor when replacing it with a new one. If sensor electrolyte comes in contact with your skin, wash affected area thoroughly with soap and water.

1. Turn off the controller.

2. Turn off or unplug incoming power at the controller.

3. Unscrew the bottom section of the H2S detector housing from the top section.

4. Unplug and remove the H2S sensor with the rubber boot and spacer attached.

5. Remove the rubber boot and spacer from the old sensor.

6. Install the spacer and rubber boot onto the replacement sensor’s face.

7. Carefully plug the replacement sensor into the socket pattern that is located in the top section of the detector housing.
   NOTE: Match the sensor’s male pins with the four female sockets as you plug the sensor into the socket.

8. Screw the bottom section of the detector housing onto the top section.

9. Turn on or plug in incoming power at the power source end.

10. Turn on the controller.
    CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue with the next step.

11. Calibrate the replacement sensor as described in the Calibration section of this manual.

Replacing the Amplifier

1. Turn off the controller.
2. Turn off or unplug incoming power at the power source end.
3. Remove the junction box cover.
4. Disconnect the detector leads from the detector terminal strip.
5. 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.
6. Remove the amplifier.
7. Place the new amplifier in the same position as the old amplifier.
8. Use the two screws you removed in step 5 to secure the new amplifier to the junction box.
9.  Verify that the jumper block is installed over the TOXIC selector of the amplifier type selector as shown in Figure 3.
10. Reconnect the wiring from the controller to the interconnect terminal strip as shown in Table 2 and Figure 3.
    Table 2: Reconnecting the H2S Amplifier to a Controller Amplifier Interconnect Terminal Strip| Controller Transmitter Terminal Strip (typical)
    ---|---
    4/20 FB| 4 -20 (FB)
    24V +| + V (11 – 30 VDC)
11. Reconnect the detector leads to the detector terminal strip as shown in Table 3 and Figure 3.

Table 3: Reconnecting the H2S Detector to the Amplifier

12. Reinstall the junction box cover.

13. Turn on or plug in incoming power at the power source end.

14. Turn on the controller.
    CAUTION: Allow the sensor to warm up for 5 minutes before you continue with the next step.

15. Calibrate the H2S transmitter as described in the Calibration section of this manual.

Replacing the H2S Detector

NOTE: In most cases, it is only necessary to replace the H2S sensor.

1. Turn off the controller.

2. Turn off or unplug incoming power at the power source end.

3. Remove the junction box cover.

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

5. Unscrew the detector from the junction box.

6. Guide the detector leads of the replacement detector through the bottom conduit hub of the junction box, then screw the mounting threads of the detector into the conduit hub.

7. Connect the detector leads to the detector terminal strip as shown in Table 4 and Figure 3
   Table 4: Connecting the Replacement H2S Detector to the Amplifier
   H 2S Detector Lead| Amplifier Interconnect Terminal Strip
   ---|---
   Black| TOXIC BK
   Red| TOXIC RD

8. Reinstall the junction box cover.

9. Turn on or plug in incoming power at the controller.

10. Turn on the controller.
    CAUTION: Allow the replacement detector to warm up for 5 minutes before you continue with the next step.

11. Calibrate the replacement detector as described in the Calibration section of this manual.

12. Secure the junction box cover to the junction box.

Calibration Frequency

Although there is no particular calibration frequency that is correct for all applications, a
calibration frequency of every 3 months is adequate for most H2S transmitter applications.

Unless experience in a particular application dictates otherwise, RKI Instruments, Inc. recommends a calibration frequency of every 3 months for the H2S transmitter.

If an application is not very demanding, for example detection in a clean, temperature controlled environment, and calibration adjustments are minimal at calibration, then a calibration frequency of every 6 months is adequate.

If an application is very demanding, for example if the environment is not well controlled, then more frequent calibration than every 3 months may be necessary

Calibration

This section describes how to calibrate the H2S transmitter. It includes procedures to prepare for calibration, set the zero reading, set the response reading, and return to normal operation.

It describes the test using a calibration kit that includes a calibration cup, calibration gas, sample tubing, and a fixed flow regulator with an on/off knob. RKI Instruments, Inc. recommends using a 0.5 LPM (liters per minute) fixed flow regulator.

Preparing for Calibration

NOTE: Calibrating the H2S transmitter may cause alarms. Be sure to put the controller into its calibration program or disable external alarms before calibration.

1. Screw the calibration cup onto the bottom of the H2S detector.

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

3. Use the sample tubing to connect the fixed flow regulator to the calibration cup.

4. Set a voltmeter to measure in the millivolt (mV) range.
   WARNING: Do not remove the sensor cap or junction box cover while the circuits are energized unless the area is determined to be non-hazardous. Keep the sensor cap and junction box cover tightly closed during operation.

5. 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-.

6. 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 25 PPM H2S and a fullscale setting of 100 PPM, the correct output is 200 mV.

200 (mV) = (25/100) X 400 +100

Setting the Zero Reading

NOTE: If you can verify that the H2S transmitter is in a fresh air environment, you do not need to apply zero air to the detector before adjusting the zero reading.

1. Turn the regulator on/off knob counterclockwise to open it. Gas will automatically begin to flow.
2. Allow the gas to flow for two minutes.
3. Verify a reading of 100 mV (± 2mV).
4. If necessary, use the zero pot on the amplifier to adjust the reading to 100 mV (± 2mV).
5. Unscrew the regulator from the zero air calibration cylinder. Leave the sample tubing connected to the regulator and the calibration cup.

Setting the Response Reading

1.  Verify that the calibration gas is representative of the transmitter’s target gas.
2. For toxic gas cylinders (like H2S), it is important to vent the regulator while installing it onto the cylinder. Venting the regulator during installation helps prevent air from getting into the cylinder and degrading the gas. Open the regulator by turning the knob counterclockwise and then install it onto the cylinder.
3. Allow the gas to flow for two minutes.
4. Verify that the reading matches the response reading (± 2mV) you determined earlier.
5. If necessary, use the span pot on the amplifier to adjust the reading to match the correct response reading.
6. Turn the regulator on/off knob clockwise to close it.
7. Unscrew the regulator from the calibration cylinder.
8. Unscrew the calibration cup from the detector.

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

Returning to Normal Operation

1. Remove the voltmeter leads from the amplifier test points.
2. Secure the junction box cover to the junction box.
3. When the display reading falls below the alarm setpoints, return the controller to normal operation.
4. Verify that the controller display reading decreases and stabilizes at 0 ppm.
5. Store the components of the calibration kit in a safe and convenient place.

Parts List

able 5 lists replacement parts and accessories for the H2S transmitter.

Table 5: Parts List

classified
65-2428| H2S replacement detector assembly (includes sensor), CSA classified
71-0113RK| 65-2422RK-05 H 2S Transmitter Operator’s Manual (this document)
81-0076RK-01| Zero air calibration cylinder, 34 liter steel
81-0151RK-04| Calibration cylinder, 25 PPM H2S in nitrogen, 34 liter aluminum
81-1050RK| Regulator with gauge and knob, 0.5 LPM, for 17 liter and 34 liter steel calibration cyl- inders (cylinders with external thread)
81-1051RK| Regulator with gauge and knob, 0.5 LPM, for 34 liter aluminum calibration cylinders and 58 liter and 103 liter steel calibration cylinders (cylinders with internal thread)
81-1117RK| Calibration cup
ES-1537-H2S| H2S replacement sensor

81-1117RK Calibration cup

ES-1537-H2S H2S replacement sensor
1.888.610.7664 www.calcert.com sales@calcert.com

References

• Calcert

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