RKI INSTRUMENT 61-1001-05SS Hydrogen Detector Instruction Manual

RKI INSTRUMENT 61-1001-05SS Hydrogen Detector

Overview

This manual describes the 61-1001-05SS hydrogen detector (internal amplifier type). This manual also describes how to install, start up, maintain, and calibrate the detector when it is used with a gas monitoring controller. A parts list at the end of this manual lists replacement parts and accessories for the hydrogen detector. The 61-1001-05SS hydrogen detector includes the NC-6205-05 hydrogen detector and a junction box. This type of detector is meant to be installed in an inaccessible area. A tube can be installed on the calibration cup and be routed to an accessible area.

Specifications

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

Table 1 lists the specifications for the hydrogen detector.

Table 1: 61-1001-05SS Specifications

WARNING : When using the 61-1001-05SS, you must follow the instructions and warnings in this manual to assure proper and safe operation of the 61-1001-05SS and to minimize the risk of personal injury. Be sure to maintain and periodically calibrate the 61-1001-05SS as described in this manual.

Description

This section describes the components of the 61-1001-05SS detectors. The 61-1001-05SS includes the NC-6205-05 hydrogen detector, a calibration cup with diffuser holes, and a junction box. A four point terminal strip is provided inside the junction box for detector connections.

NC-6205-05 Hydrogen Detector
The hydrogen detector is a catalytic type detector that produces an electrical output that corresponds to the detection range. It is packaged in a 1/2 NPT nipple with a sintered metal flame arrestor on one end allowing ambient air to diffuse into the detector. The flame arrestor also contains any sparks which may occur within the detector. The detector has a built in molecular sieve that only allows hydrogen to diffuse into the detector. The 1/2 NPT mounting threads at the top of the detector allow you to mount it into the bottom conduit hub of the junction box. A flame arrestor guard screws onto the bottom of the detector (flame arrestor end). The flame arrestor guard protects the flame arrestor from damage and is permanently bonded to the detector housing. Four color-coded leads extend from the top of the detector. The leads allow you to connect the detector to the amplifier.

Junction Box
The stainless steel, corrosion resistant detector junction box is intended to be installed remotely from the M2A junction box. The combustible gas detector is factory-installed in the bottom 3/4 NPT conduit hub using a 3/4 x 1/2 NPT reducer. A terminal strip is provided for wiring connections and the detector is factory wired to one side of this terminal strip. This wiring should go through the top 3/4 NPT conduit hub. An O-ring seals the interface between the junction box cover and the junction box base. A locking set screw on the junction box cover allows you to secure the junction box cover and prevent it from being removed.

Installation

This section describes procedures to mount the hydrogen detector in the monitoring environment and wire the detector to a controller.
Mounting the Hydrogen Detector

1. Select a mounting site that is representative of the monitoring environment. Consider the following when you select the mounting site.
2. Select a site where the detector is not likely to be bumped or disturbed. Make sure there is sufficient room to perform start-up, maintenance, and calibration procedures.
3. Select a site where the target gas is likely to be found first. For hydrogen, which is lighter than air, mount the detector near the ceiling or where hydrogen is most likely to accumulate.
4. At the mounting site you select, hang or mount the junction box with the detector facing down (see Figure 2).
5. Install 3/16 inch I.D. flexible polyurethane tubing to the fitting at the bottom of the calibration cup and route it to an accessible area that is close to the controller. See the “Parts List” on page 17 for available tubing.

Wiring the Hydrogen Detector to a Controller

WARNING : Always verify that the power to the controller is off before you make wiring connections.

1. Turn off the controller.

2. Turn off the power to the controller.

3.  Remove the junction box cover.

4. Guide a four-conductor, shielded cable or four wires in conduit through the unused conduit hub of the junction box. Use appropriate conduit fittings and construction techniques for the environmental rating and hazardous location classification of the junction box. The junction box is rated NEMA 4X and classified explosion-proof for Class I, Groups B, C, and D.

5. Connect the wires to the terminal block in the junction box.
   CAUTION: If using a shielded cable, leave the drain wire insulated and disconnected at the detector. You will connect the opposite end of the cable’s drain wire to the controller.

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

7. Route the cable or wires leading from the hydrogen detector through one of the conduit hubs at the controller housing. Use appropriate conduit fittings and construction technique for the environmental rating of the controller. RKI controllers are typically rated NEMA 4X.
   CAUTION : Do not route power and detector wiring through the same conduit hub. The power cable may disrupt the transmission of the detector signal to the controller.

8. Connect the wires to the applicable controller terminal strip. See the controller operator’s manual and the controller’s detector head specification sheet for the
   61- 1001-05SS detector.

9. If using a shielded cable, connect the cable’s drain wire to an available chassis ground at the controller. RKI controllers typically have a ground stud that is a convenient grounding location.

Start-Up

This section describes procedures to start up the hydrogen detector and place the detector 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 operator’s manual.
3. Turn on the power to the controller.
4. Turn on the controller.
5. Verify that the controller is on and operating properly. Refer to the controller operator’s manual.

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

Setting the Zero Reading

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

CAUTION : If you suspect the presence of hydrogen in the monitoring environment, use the zero air calibration cylinder to introduce “fresh air” to the detector and verify an accurate zero reading.

1. Verify that the detector is in a fresh air environment (an environment known to be free of hydrogen and of normal oxygen concentration, 20.9%).

2. Verify a reading of 0% LEL at the controller.
   If the display reading is 0% LEL, start-up is complete. The hydrogen detector is in normal operation. If the display reading is not 0% LEL, continue with step 3.

3. Perform a zeroing operation at the controller. See the controller operator’s manual for directions.

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 hydrogen detector. It includes daily and quarterly procedures.

• Daily
  Verify a display reading of 0% LEL at the controller. Investigate significant changes in the reading.

• Quarterly
  Calibrate the detector 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 hydrogen detector.

NOTE: This troubleshooting guide describes detector problems only. See the controller operator’s manual for problems you may encounter with the controller.

Table 2:Troubleshooting the Hydrogen Detector

Condition| Symptom(s)| Probable Causes| Recommended Action
---|---|---|---
Fail Condi-| •   Controller indicates| •   The detector wiring| 1.    Verify that the detector wiring is correct and secure.

2.    Calibrate the detector.

3.    If the fail condition continues, replace the detector.

4.    If the fail condition continues, contact RKI for further instruction.

tion| a fail condition.| is disconnected or

misconnected.

 |  | •   The detector zero
 |  | the signal is low enough
 |  | to cause a fail
 |  | condition.
 |  | •   The detector is
 |  | malfunctioning.
Condition| Symptom(s)| Probable Causes| Recommended Action
---|---|---|---
Slow or No| •   Unable to| •   The calibration cylinder is low, out- dated, or defective.

•   The calibration gas is not an appropriate concentration.

•   The detector is malfunctioning.

•   The flexible tubing to the calibration cup has become kinked, blocked, or disconnected.

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

2.    Verify that the calibration gas concentration is appropriate for the detector.

3.    Verify that the flexible tubing to the calibration cup is clear and connected to the calibration cup.

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

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

Response/| accurately set the
Difficult or| zero or response
Unable to| reading during
Calibrate| calibration.
 | •   Detector requires
 | frequent
 | calibration.
 | NOTE: Under
 | “Normal”
 | circumstances, the
 | detector requires
 | calibration once
 | every three months.
 | Some applications
 | may require more
 | frequent calibration
 |

Replacing the Hydrogen Detector

1. Turn off the controller.

2. Turn off the power to the controller.

3. Remove the junction box cover.

4. Disconnect the detector leads from the terminal block in the junction box. Note the position of the color-coded leads as you remove them.

5. Unscrew the detector from the junction box conduit hub.

6. Guide the detector leads of the replacement detector through the junction box conduit hub, then screw the mounting threads of the detector into the hub. If necessary for environmental conditions, apply thread sealant or Teflon tape to the hub and/or detector threads to seal them.

7. Connect the detector leads to the terminal block the same way the old detector was wired (see Figure 3).
   See the controller operator’s manual and the controller’s detector head specification sheet for the 61-1001-05SS detector to verify the connections to the controller are correct.

8. Reinstall the junction box cover.

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

10. Turn on the controller and place it into normal operation.
    CAUTION: Allow the replacement detector to warm up for 5 minutes before you continue with the next step.

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

Calibration Frequency

• Although there is no particular calibration frequency that is correct for all applications, a calibration frequency of every 3 to 6 months is adequate for most hydrogen detector applications. Unless experience in a particular application dictates otherwise, RKI Instruments, Inc. recommends a calibration frequency of every 3 months.
• If an application is not very demanding, for example, detection in a clean, temperature controlled environment where hydrogen is not normally present and calibration adjustments are minimal at calibration, then a calibration frequency of every 6 months is adequate.
• If an application is very demanding, for example, if hydrogen is present often and in significant concentrations or the environment is not well controlled, then more frequent calibration than every 3 months may be necessary. If potential catalyst poisons are known or likely to be present, more frequent calibration than every 3 months will be necessary.

Determining Response Time

Since the detector is meant to be installed in an inaccessible area, the response time of the detector will depend on the length of flexible tubing that is attached to the calibration cup. To determine the response time based on the length of tubing connected:

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

2. Note the current gas reading displayed at the controller.

3. Screw the regulator into the calibration cylinder. Do not use a zero-air cylinder for this operation.

4. Use the flexible tubing coming from the calibration cup to connect the regulator to the calibration cup.

5. Turn the regulator’s on/off knob counterclockwise to open the regulator. Gas will begin to flow. Take note of the time or start a stopwatch.

6. When you first start to notice an increase in the gas reading, note how much time passed between starting the gas flow and noticing a reading response.

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

8. Unscrew the regulator from the calibration cylinder.

9. Disconnect the calibration cup’s flexible tubing from the regulator.
   NOTE : Do not disconnect the flexible tubing from the calibration cup.

10. Add 1 minute to the length of time determined in Step 6. This is the response time for the detector. When performing a response test, zero adjustment, or span adjustment, gas must be applied for this length of time.

Calibration

This section describes how to calibrate the hydrogen detector. It includes procedures to prepare for calibration, set the zero reading, set the response reading, and return to normal operation.
WARNING : The controller is not an active gas monitoring device during the calibration procedure.

NOTE : The following procedure assumes the use of a calibration kit which includes a calibration gas cylinder, and a 0.5 LPM fixed flow regulator.

Preparing for Calibration

1. Use the flexible tubing coming from the calibration cup to connect the regulator to the calibration cup.
2. Place the controller into its calibration program or disable external alarms.

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

Setting the Zero Reading

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

1. Screw the regulator into the zero air calibration cylinder.
2. Follow the directions in the controller operator’s manual for setting the zero reading.
3. When the instructions call for applying zero air to the detector, turn the regulator’s on/off knob counterclockwise to open it.
4. Allow zero air to flow for the length of time determined in “Determining Response Time” on page 14.
5. Set the zero reading according to the controller operator’s manual
6. Turn the regulator’s on/off knob clockwise to close it.
7. Unscrew the regulator from the zero air cylinder.
8. Leave the calibration cup’s flexible tubing connected to the regulator and the calibration cup

Setting the Response Reading

1. Screw the regulator into the calibration gas cylinder.
2. Follow the directions in the controller operator’s manual for setting the response reading (span).
3. When the directions call for exposing the detector to gas, turn the regulator’s on/off knob counterclockwise to open it.
4. Allow calibration gas to flow for the length of time determined in “Determining Response Time” on page 14.
5. After setting the response reading, turn the regulator’s on/off knob clockwise to close it.
6. Unscrew the regulator from the cylinder.

Returning to Normal Operation

1. Disconnect the calibration cup’s flexible tubing from the regulator.
   NOTE : Do not disconnect the flexible tubing from the calibration cup.

2. When the controller display reading falls below the alarm points, return the controller to normal operation.
   NOTE: If you do not allow the gas reading to decrease below the alarm points, then unwanted alarms may occur.

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

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

Parts List

Table 3 lists replacement parts and accessories for the 61-1001-05SS hydrogen detector.

when ordering)
07-7151RK| O-ring for junction box
10-5153RK| Lid-locking set screw
18-0416RK-01| Junction box with cover, stainless steel
71-0664| 61-1001-05SS Hydrogen Detector Operator’s Manual (this document)
81-0002RK-01| Calibration cylinder, 50% LEL hydrogen in air, 34 liter steel
81-0002RK-03| Calibration cylinder, 50% LEL hydrogen in air, 103 liter
81-0076RK-01| Zero air calibration cylinder, 34-litre steel
81-0076RK-03| Zero air calibration cylinder, 103-liter
81-1050RK| Regulator, with gauge and knob, 0.5 litre/minute continuous flow, for 17-litre and 34-litre steel calibration cylinders (cylinders with external threads)
81-1051RK| Regulator, with gauge and knob, 0.5 litre/minute continuous flow, for 34-litre aluminum/58 litre/103-litre calibration cylinders (cylinders with internal threads)
NC-6205-05| Replacement hydrogen detector, CSA type

WARNING
Read and understand this instruction manual before operating the instrument. Improper use of the gas monitor could result in bodily harm or death. Periodic calibration and maintenance of the gas monitor is essential for proper operation and correct readings. Please calibrate and maintain this instrument regularly! The frequency of calibration depends upon the type of use you have and the sensor types. For most applications, typical calibration frequencies are between 3 and 6 months but can be more often or less often based on your usage.

Warranty

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 the 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. Parts must be returned to RKI Instruments, Inc. for repair or replacement. 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:

• Absorbent cartridges
• Fuses
• Pump diaphragms and valves
• Batteries
• Filter elements

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or repair procedures, not in accordance with an instruction 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 only 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. The warranty covers parts and labour performed at RKI Instruments, Inc. only, and does not cover field labour or shipment of parts back to RKI.

RKI Instruments, Inc. www.rkiinstruments.com

References

• RKI Gas Detectors - Portable Gas Monitors - LEL, PID, H2S, CO, O2 Sensors
• RKI Gas Detectors - Portable Gas Monitors - LEL, PID, H2S, CO, O2 Sensors

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