RKI Instruments GD-K7D2 User manual

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

Model GD-K7D2 (24VDC)

Sample Draw Detector

Operator’s Manual

Part Number: 71-0078RK

Revision: 0

Released: November 18, 2002

2 • Model GD-K7D2 (24 VDC) Sample Draw Transmitter

ProductWarranty

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:

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or

repair procedures not in accordance with instruction manual.This warranty indicates the

full extend 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 LIMITEDTO, THEWARRANTY 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

PRODUCTSTO 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.Warranty covers parts and labor performed at RKI Instruments, Inc.only, and does

not cover ﬁeld labor or shipment of parts back to RKI.

a) Pump diaphragms and valves c) Batteries

b) Fuses d) Filter elements

Model GD-K7D2 (24 VDC) Sample Draw Transmitter • 3

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Speciﬁcations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Detection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Disassembling the GD-K7D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting the GD-K7D2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Connecting Sample Lines to the GD-K7D2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Wiring the GD-K7D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Assembling the GD-K7D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Storing the GD-K7D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Replacing Components of the GD-K7D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Assembling the Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4 • Model GD-K7D2 (24 VDC) Sample Draw Transmitter

Overview

This manual describes the 24 VDC version of the Model GD-K7D2 sample draw 4 - 20 mA

transmitter detector head. This manual also describes how to install, start up, maintain,

and calibrate the GD-K7D2 when it is used with a gas monitoring controller. Aparts list at

the end of this manual lists replacement parts and accessories for the

GD-K7D2.

Speciﬁcations

Table 1 lists speciﬁcations for the 24 VDC version of the GD-K7D2.

Table 1: Speciﬁcations

Target Gas & Detector Range Refer to the RKI Instruments Inc. List of Detectable Gasses

Area Classiﬁcation Indoor, non-hazardous locations

Sampling Method Sample-draw

Input Power 24 VDC

Signal Output 4 to 20 mA

Response Time 90% in 60 seconds

Accuracy ± 10% of fullscale

Flow Rate Approximately 0.5 liters/minute

Recommended Sample Tubing 4 mm I.D. x 6 mm O.D. Teﬂon PTFE

Recommended Sample Tubing Length See Table 2 in the Installation section on p. 10

Model GD-K7D2 (24 VDC) Sample Draw Transmitter • 5

Description

This section describes the components of the GD-K7D2. The GD-K7D2 consists of three

separate sections: the cover, the detection unit, and the installation bracket. The detection

unit (front section) includes the ﬂow system and gas detection components. The L-shaped

installation bracket (rear section) includes installation components including a terminal

strip, tube ﬁttings and a card edge connector socket.

The detection unit and installation bracket are secured together by a captive screw located

in the bottom right of the detection unit. The detection unit’s main circuit board plugs into

the socket on the installation bracket. The socket is above the terminal strip.

Figure 1: Sections of the GD-K7D2

A hydrophobic sample ﬁlter is also provided with the GD-K7D2 for installation near the

sample in ﬁtting. The ﬁlter scrubs particulates out of the sample stream and keeps water

and many other liquids from entering the GD-K7D2 ﬂow system.

Cover

The painted steel cover slides over both the detection unit and installation bracket. It is

radio frequency (RF)- and dust-resistant. A thumbscrew on the front of the cover near the

bottom secures the cover to the installation bracket (see Figure 1). The cover includes a

label on the front that indicates the target gas and detection range of the GD-K7D2.

Cover

Detection Unit

Installation Bracket

6 • Model GD-K7D2 (24 VDC) Sample Draw Transmitter

The ﬂow light and ﬂowmeter are visible through the cover. The ﬂow rate potentiometer

(pot) is accessible through cover.

Figure 2: GD-K7D2 Cover Components

Detection Unit

The detection unit includes the main circuit board, ﬂowmeter, gas sensor, ampliﬁer,

pump, and lithium battery pack.

Figure 3: Detection Unit Component Location

GAS DETECTOR

MODEL GD-K7D

FLOW

ADJ.

Flowmeter

Flow light

Flow rate

potentiometer

ID card holder

Gas name

card holder

Thumbscrew

TP1 (+)

TP2 (+) mA

Output

Factory Adjust Pot

Gain Pot

(Factory Adjust)

Span Pot

Zero Pot

Low Flow

Sensor

Flowmeter

Factory Adjust Pot

ON/OFF Switch

Flow Rate Pot

Flow Light Lithium Battery

Pack

Gas Sensor

Sample Adapter

Sensor Retaining

Clamp

Main Circuit Board

Fuse

Captive Retaining Screw

Amplifier

Pump

Bracket

Pump

Model GD-K7D2 (24 VDC) Sample Draw Transmitter • 7

Main Circuit Board

The main circuit board includes the ﬂow light, ﬂow rate pot, ON/OFF switch and fuse.

The end of the board at the rear of the detection unit plugs into a socket on the installation

bracket.

Flow light

The ﬂow light is at the top left corner of the detection unit (see Figure 2 and 3). The green

ﬂow light is on when the GD-K7D2’s ﬂow rate is at an acceptable ﬂow rate. If the ﬂow rate

drops below or rises above the acceptable ﬂow rate, the ﬂow light turns off.

Flow rate pot

The ﬂow rate pot is to the right of the ﬂow light (see Figure 2 and 3). You can adjust the

GD-K7D2’s ﬂow rate with the ﬂow rate pot. The pot is accessible through a hole in the

cover.

ON/OFF switch

The ON/OFF switch is to the right of the ﬂow rate pot (see Figure 3). The On/Off switch

turns the GD-K7D2 on and off. The switch is in the ON position when the toggle switch is

in the right position.

Fuse

A 2 amp, 5 mm x 20 mm fuse is located on the middle left of the main board. It is

accessible by removing four screws that retain a metal cover over the main board.

Flowmeter

The ﬂowmeter is below the ﬂow light (see Figure 2 and 3).A ball in the ﬂowmeter column

indicates the ﬂow rate of the GD-K7D2. Two horizontal lines on the ﬂowmeter mark the

acceptable ﬂow rate for the GD-K7D2. Use the ﬂow rate pot to keep the ﬂowmeter ball

between the two lines. A ﬂow sensor at the bottom of the ﬂowmeter senses when the

ﬂowmeter ball is low enough to be at the bottom of the ﬂowmeter and initiates a low ﬂow

alarm

Gas Sensor

The gas sensor is below and to the right of the ﬂowmeter (see Figure 3).Through a series of

electrical and chemical reactions, the gas sensor produces an electrical current that is

proportional to the detection range of the target gas in the test sample. Electrodes within

the gas sensor housing are surrounded by liquid electrolyte. The chemical and electrical

reactions are facilitated by the electrolyte.

A sample adapter is attached to the front of the sensor. It directs the sample over a gas

permeable membrane on the front of the sensor and into the sensor.

Ampliﬁer

The ampliﬁer is to the right of the sensor (see Figure 3). The ampliﬁer converts the output

of the sensor to a 4 to 20 mA signal (that is proportional to the detection range of the GD-

K7D2) and transmits the signal to a controller. The ampliﬁer includes the span pot, zero

pot, gain pot, and output check pins.

Span pot

The span pot is at the top of the ampliﬁer. Use the span potentiometer to adjust the

GD-K7D2’s response output during the calibration procedure.

Zero pot

The zero pot is below the span pot. Use the zero pot to adjust the GD-K7D2’s fresh air

8 • Model GD-K7D2 (24 VDC) Sample Draw Transmitter

output during start-up and calibration procedures.

Gain pot

The gain pot is below the zero pot. It is used to make coarse span adjustments.

The gain

pot is factory set and for adjustment by a ﬁeld service technician only

Another factory adjust pot is located below the gain pot. Do not adjust this pot.

Output check pins

Two output check pins [marked

1 (+)

and

2 (-)

]are below the pots. Use the output check

pins to read the signal output of the GD-K7D2 with a milliampmeter during the start-up

and calibration procedures.

Pump

The pump is behind the sensor. The pump pulls the test sample into the GD-K7D2. The

pump operates on AC voltage that is generated by the GD-K7D2 from the 24 VDC input

power.

Lithium Battery Pack

A 3.6 volt lithium battery pack is above the pump on the right side of the GD-K7D2. The

lithium battery pack maintains a bias voltage on the gas sensor when the GD-K7D2 is not

receiving incoming power, such as during shipment or storage. If the GD-K7D2 is off

power for an extended period and the lithium battery pack is dead, the gas sensor

operation will be affected when the GD-K7D2 is started up. See Storing the GD-K7D2 in

the Maintenance section for battery pack replacement recommendations.

Installation Bracket

The L-shaped installation bracket facilitates mounting and wiring of the GD-K7D2. The

three mounting holes on the back of the bracket are used to mount it to a vertical surface.

The installation bracket includes the socket, external wiring terminal strip, cable bushing,

and sample ﬁttings.

Socket for

Main Board

External Wiring

Terminal Strip

Mounting Holes

Cable Bushing

Gas In

Sample Fitting

Gas Out

SampleFitting

Factory Installed

Jumper*

*Jumper is factory installed when

GD-K7D2 is used with a controller

that does not have a built in flow

alarm circuit and flow alarm

wiring terminals.

Model GD-K7D2 (24 VDC) Sample Draw Transmitter • 9

Figure 4: Installation Bracket Component Location

Socket

Acard edge connector socket on the back of the bracket mates with the main circuit board

on the detection unit.

ExternalWiring Terminal Strip

Aseven point terminal strip is located below the socket and used for wiring the GD-K7D2

to a controller.

A jumper is normally factory installed between the second and third terminals from the

right. This jumper is installed when the GD-K7D2 is used with a controller that does not

have a ﬂow alarm circuit and ﬂow alarm terminals for wiring to the GD-K7D2. It is not

installed when the GD-K7D2 is used with a controller that has ﬂow alarm circuitry and

ﬂow alarm terminals. See Wiring the GD-K7D2 to a Controller in the Installation section

for both types of wiring.

Cable Bushing

The 1/2 in. (1.25 cm) cable bushing on the bottom of the bracket allows you to route

wiring from a controller to the seven point external wiring terminal strip on the back of

the bracket.

Gas In & Gas Out Sample Fittings

There are two tube ﬁttings on the bottom of the bracket, the gas in and gas out sample

ﬁttings. The gas in ﬁtting is forward of the gas out ﬁtting. The gas in ﬁtting allows sample

to enter the GD-K7D2 and the gas out ﬁtting is for exhausting the sample. Both ﬁttings

accept 6 mm O.D. x 4 mm I.D. Teﬂon PTFE tubing.

10 • Model GD-K7D2 (24 VDC) Sample Draw Transmitter

Installation

This section describes how to install the GD-K7D2 at the monitoring site. This section

includes procedures to disassemble the GD-K7D2, mount the GD-K7D2, connect sample

lines to the GD-K7D2, and wire the GD-K7D2 to a controller.

Disassembling the GD-K7D2

1. Loosen the thumbscrew on the front of the housing cover, then remove the cover from

the detection unit and installation bracket.

2. Loosen the captive screw in the lower left front of the detection unit that secures it to

the installation bracket.

3. Pull the detection unit away from the installation bracket until the main board

disengages from the socket, then lift it up slightly to free the detection unit from the

installation bracket.

Mounting the GD-K7D2

CAUTION:

The GD-K7D2 is suitable for installation in indoor areas where general purpose

equipment is in use.

1. Select a mounting site that is representative of the monitoring environment. Consider

the following when you select the mounting site.

•Select a site that is easily accessible for servicing.

•Select a site where the GD-K7D2 is not likely to be bumped or disturbed. Make

sure there is sufﬁcient room to make wiring and sample line connections at the

bottom of the GD-K7D2. Also make sure there is sufﬁcient room to perform

start-up, maintenance, and calibration procedures.

•Select a site near the sampling area. The GD-K7D2 is designed to detect a variety

of toxic gases many of which are easily absorbed in sample tubing. See Table 2

below for recommended sample tubing lengths for various gases when using

Teﬂon PTFE sample tubing. Contact RKI Instruments, Inc. for gases not listed.

2. Use three #10 screws through the three mounting holes in the installation bracket to

mount the installation bracket to a vertical surface. One of the mounting holes is

round and the other two are slotted (See Figure 5).

Table 2: Maximum Sample Tubing Lengths For Various Gases

Target Gas Maximum Sample

Tubing Length

(HF), ClF

, ClO

, F

, HF, O

, POCl

(HCl), WF

, TaF

(HF) 5 meters

BCl

(HCl), BR

, HBr, HCl, F

, NO, NO

, PCl

(HCl), POCl

SbCl

(HCl), SiH

(HCl), SnCl

(HCl), SiCl

(HCl), SO

, TiCl

(HCl)

10 meters

, Si

20 meters

AsH

, B

, CO, H2S, NH3, PH

, SiH

30 meters

Note: Gas in parenthesis indicates breakdown product of target gas being detected.

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