0,000 ppm Gas Tracer Operator’s Manual Part Number: 71-0265RK Revision: 0 Released: 12/5/12 www.rkiinstruments.
WARNING Read and understand this instruction manual before operating 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! Frequency of calibration depends upon the type of use you have and the sensor types.
Warranty RKI Instruments, Inc. warrants the 10,000 ppm Gas Tracer sold by us to be free from defects in materials, workmanship, and performance for a period of two years from the date of shipment from RKI Instruments, Inc. This includes the instrument and the original sensors. Replacement parts are warranted for 1 year from the date of their shipment from RKI Instruments, Inc. except for replacement sensors which are warranted for 2 years.
Table of Contents Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About the 10,000 ppm Gas Tracer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turning on the Gas Tracer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performing a Fresh Air Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responding to Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Updating the Alarm Point Settings . . . . . . . . . . . . . . . . . . . . . . . . . Turning the Clear Data Logger Screen On or Off. . . . . . . . . . . . . . . Turning the Bump Test Function On or Off . . . . . . . . . . . . . . . . . . . Turning the Pump Off Screen On or Off . . . . . . . . . . . . . . . . . . . . . Updating the Bump Test Parameters . . . . . . . . . . . . . . . . . . . . . . . . Updating the Confirmation Beep Setting . . . . . . . . . . . . . . . . . . . . .
Appendix A: Calibrating with a Sample Bag . . . . . . . . . . . . . . . 97 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Calibration Supplies & Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Preparing for Calibration or Bump Test . . . . . . . . . . . . . . . . . . . . . . . . 98 Normal Operation Fresh Air Adjustment. . . . . . . . . . . . . . . . . . . . . 98 Filling the Gas Bag . . . . . . . . . . . . . . . . . . . .
Chapter 1: Introduction Overview This chapter briefly describes the 10,000 ppm Gas Tracer. This chapter also describes the 10,000 ppm Gas Tracer Operator’s Manual (this document). Table 1 at the end of this chapter lists the specifications for the 10,000 ppm Gas Tracer. About the 10,000 ppm Gas Tracer Using an advanced detection system, the 10,000 ppm Gas Tracer sample draw gas monitor detects the presence of combustible gas in the 0-10,000 ppm range.
WARNING: When using the 10,000 ppm Gas Tracer, you must follow the instructions and warnings in this manual to assure proper and safe operation of the unit and to minimize the risk of personal injury. Be sure to maintain and periodically calibrate the 10,000 ppm Gas Tracer as described in this manual.
Specifications Table 1: 10,000 ppm Gas Tracer Specifications Target Gas Combustible Gas; calibrated to methane Range (Increment) 0-9990 ppm (10 ppm) NOTE: Detection range is 0-9990 ppm, but displayed range can be 0-1000, 0-2000, 0-4000 or 0-9990 ppm. Sampling Method Sample Draw Response Time T90 Within 30 Seconds Accuracy ± 30 ppm or ± 5% of reading (whichever is greater) Display Digital LCD Display Gas Alarms There are no gas alarms in the 10,000 ppm Gas Tracer.
Dimensions and Weight Approximately 171(H) x 65(W) x 39(D) mm (5.6”H x 2.5”W x 1.5”D) Approximately 310 g (11 oz.) About this Manual The 10,000 ppm Gas Tracer Operator’s Manual uses the following conventions for notes, cautions, and warnings. NOTE: Describes additional or critical information. CAUTION: Describes potential damage to equipment. WARNING: Describes potential danger that can result in injury or death.
Chapter 2: Description Overview This chapter describes the Gas Tracer instrument and accessories. Instrument Description The instrument includes the case, sensor, LCD, control buttons, printed circuit boards, alarm LED’s, infrared communication port, buzzer, vibrator, batteries, pump, flow chamber, and inlet filter holder.
Rechargeable Version Alkaline Version Battery Pack Battery Pack Release Latch Battery Cover Release Knob Figure 2: Components of the Gas Tracer, Bottom Case The Gas Tracer’s sturdy, high-impact plastic case is radio frequency (RF) resistant and is suitable for use in many environmental conditions, indoors and out. The case is dust proof and weather resistant. A rubber layer on the outside of the case protects it from scratches and impact damage.
displayed on the LCD. The Gas Tracer has 4 dummy sensors installed. Dummy sensors are factory installed. The flat top of the dummy sensor should face up and the bottom hollow side should face down.
LCD A digital LCD (liquid crystal display) is visible through a clear plastic window on the front of the case. The LCD display shows the gas reading. The display also shows information for each of the Gas Tracer’s program modes. Control Buttons Five control buttons are located below the LCD. They are arranged around a central button, the POWER ENTER button. The DISPLAY (ADJ) button is on the left, the RESET SILENCE button on the right, the AIR▲ button on the top, and the (SHIFT)▼ is on the bottom.
Gas Tracer to a computer using the GX-2012 Data Logger Management Program. See the GX-2012 Data Logger Management Program operator’s manual for data logging and downloading instructions. Buzzer One solid-state electronic buzzer is located inside the case. Holes on the top front of the case allow the sound to exit the case. The buzzer sounds for gas alarms, malfunctions, low battery voltage, and as an indicator during use of the Gas Tracer’s many display and adjustment options.
WARNING: To prevent ignition of a hazardous atmosphere, batteries must only be changed or charged in an area known to be nonhazardous. Pump A diaphragm pump inside the Gas Tracer draws the sample to the sensors. It can draw sample from as far as 50 feet from the Gas Tracer. The pump is not user serviceable. CAUTION: Sample hose lengths of more than 50 feet are not recommended for the Gas Tracer because of flow rate reduction.
Belt Clip A belt clip can be mounted to the back of the case using 3 phillips head screws. The belt clip allows the Gas Tracer to be securely attached to a belt. Wrist Strap A wrist strap is included with the Gas Tracer and can be attached to the right or left wrist strap installation feature. Sample Hose & 10 Inch Probe A 10 foot sample hose and a 10 inch probe are included as standard with the Gas Tracer.
Rechargeable Lithium Ion Battery Pack A rechargeable lithium ion battery pack is available for the Gas Tracer. A fully charged battery pack will power the Gas Tracer for 10 hours. The batteries will last for a minimum of 500 charge cycles. See the “Parts List” on page 95 for ordering information. Charging Stations The Gas Tracer lithium ion battery pack is charged with the Gas Tracer charging station.
DC Powered Charging Station An optional DC powered charging station is available with a vehicle plug 12 VDC adapter. It uses the same charging base as the AC charging station but comes with a velcro strap to secure the Gas Tracer in the charging base.
interruption of sampling and a low flow alarm if the probe tip is blocked. • 30 inch stainless steel probe Figure 8: 30 Inch Stainless Steel Probe This probe is physically the same as the 30 inch aluminum probe and is intended for applications where a high level of corrosion resistance is required in the long probe tube.
Humidifier Tube A 6 inch humidifier tube comes with any calibration kits purchased for the Gas Tracer. It is for use in calibrating the ppm combustible gas sensor. If you did not purchase a calibration kit for the Gas Tracer and purchased calibration cylinders independently, you will need to purchase a humidifier tube in order to properly calibrate the ppm combustible gas sensor. Use the humidifier tube to connect the ppm calibration cylinder to the Gas Tracer.
Chapter 3: Start Up and Operation Overview This chapter explains how to operate the Gas Tracer. The Gas Tracer only operates in Leak Check Mode and cannot be used in any other mode. Leak Check Mode is used to pinpoint small leaks of combustible gas from valves, flanges, connections, and other potential leak points. Start Up This section explains how to start up the Gas Tracer and get it ready for operation. NOTE: The battery drain is higher in Leak Check Mode.
3. Press and briefly hold down the POWER ENTER button. 4. If CL RMNDR is turned on (factory setting is OFF), and C--CHECK is set to ALL (factory setting), the screen that appears next depends on how CL EXPRD is set in the Maintenance Mode Menu (page 72). • If the unit is due for calibration and CL EXPRD is set to CONFIRM (factory setting), then the following screen displays. CAL C--LIMIT • The alarm LED’s and buzzer will pulse several times.
• If calibration is not due or CL EXPRD is set to NO EFFECT, then the following screen appears for a few seconds indicating when the next calibration is due. 2011 9 30 69d NEXT CAL 5. If BP RMNDR is turned on (factory setting is OFF), and B--CHECK is set to ALL (factory setting), the screen that appears next depends on how BP EXPRD is set in the Maintenance Mode Menu (page 72). • If the unit is due for a bump test and BP EXPRD is set to CONFIRM (factory setting), then the following screen displays.
Test” on page 54 for bump testing instructions. • If a bump test is not due or BP EXPRD is set to NO EFFECT, then the following screen appears for a few seconds indicating when the next bump test is due. 2011 9 30 10d NEXTBUMP NOTE: If both CL RMNDR and BP RMNDR are turned off, a WARM UP screen will display before the warm up sequence continues. 6. If ID DISP is turned on (see page 77), the User ID Screen displays for a few seconds and then the Station ID Screen displays for a few seconds.
7. The Date/Time Screen appears for a few seconds. 2011 8 31 22:39 DATE This screen displays the current year, month, date, and time. 8. The Battery Level and Alarm Pattern Screen appears next. bAtt 3.7 AL-H V AL -- H indicates latching (hold) alarms and AL -- A indicates selfresetting (automatic) alarms. The number shown indicates the voltage of the batteries. If the unit is powered by alkaline (dry cell) batteries, a “D” will appear before the “V” in the lower right corner. bAtt 3.
9. The display then indicates the detection units and then the full scale values for the ppm channel. CH4 CH4 CH4 9990 ppm ppm F.S. 10.The Gas Tracer will then continue its warm up. 15 sec WARM UP 11.If the Gas Tracer experiences a sensor failure during start up, a screen indicating the sensor failure displays. CH4 FAIL ppm SENSOR If the ppm sensor fails, the Gas Tracer cannot be used. Use the POWER ENTER button to turn the Gas Tracer off. Replace the failed sensor as soon as possible.
12.The Gas Tracer is now operating in Leak Check Mode. LEAK CK MODE CH4 0 ppm 9990 ppm F.S. The combustible gas reading is displayed along with the battery charge level. Performing a Fresh Air Adjustment Before using the Gas Tracer for leak checking, it is recommended to set the fresh air reading by performing a fresh air adjustment. This will set the combustible gas channel to zero. 1. Find a fresh-air environment.
Alarm Indications NOTE: False alarms may be caused by radio frequency (RF) or electromagnetic (EMI) interference. Keep the Gas Tracer away from RF and EMI sources such as radio transmitters or large motors. When a failure condition occurs, such as a sensor failure, low flow, or dead battery condition, the unit will also sound an alarm, flash the LED arrays, and vibrate. The table below summarizes the types of alarms produced by the Gas Tracer.
Table 3: Alarm Types and Indications Alarm Type Visual Indications Other Indications Sensor Failure • FAIL appears at the bottom of the display and the failed sensor is indicated • Alarm LED arrays flash Buzzer sounds a double pulsing tone (two pulses in quick succession) Clock Failure • FAIL CLOCK appears on the display • Alarm LED arrays flash Buzzer sounds a double pulsing tone (two pulses in quick succession) System Failure • FAIL SYSTEM appears on the display • Alarm LED arrays flash • Buzze
NOTE: Alarms and the back light feature consume battery power and reduce the amount of operating time remaining. Responding to Sensor Failure Alarms 1. Try calibrating the ppm sensor first, as described in “Calibration Mode” on page 35 before replacing it. 2. If the sensor failure continues, replace the ppm sensor as described in “Replacing a Sensor” on page 92. 3. If the sensor failure condition continues after you have replaced the sensor, contact RKI Instruments, Inc. for further instructions.
2. The error code meanings are shown below: Table 4: Error Code Explanation Error Code Explanation 000 MPU failure 010 RAM failure 021 EEPROM failure 031 FLASH memory failure 3. If the error code is anything but 031 as shown above, the instrument cannot be used. Contact RKI Instruments, Inc. as soon as possible. If the error code is 031, you may press and release the RESET SILENCE button to continue to normal operation if the instrument must be used temporarily.
Setting the Display Range Value The Gas Tracer Leak Check Mode has 4 display range ppm values to choose from: 1000 ppm, 2000 ppm, 4000 ppm, and 9990 ppm. NOTE: The Gas Tracer is always detecting combustible gas up to 9990 ppm. The display range value is only adjusting what part of the detection range is displayed on the LCD. To change the display range value: 1. While in Leak Check Mode, press and release the DISPLAY (ADJ) button. The display range value displayed along the bottom of the screen will change.
If you are using a display range of 1000, 2000, or 4000 ppm and the gas level goes above the display range, the full scale value of the display range will be displayed but it will not be an overscale condition unless the gas level is above 9990 ppm. If the gas level exceeds 9990 ppm, the display will indicate an overscale alarm and the ppm sensor will be shut off. LEAK CK MODE CH4 9990 9990 OVER ppm ppm Press and release the RESET SILENCE button.
on page 16. Select the desired display range. In the example below, 1000 ppm has been selected. Press and hold the (SHIFT)T button, then press and hold the AIRS button and hold both until you hear a beep. The Station ID Select Screen will display and the current station ID will be flashing. S Id SEL 001 2. Use the (SHIFT)T and AIRS buttons to scroll to the desired station ID, then press and release the POWER ENTER button to continue to the Base Reading Screen.
NOTE: If the gas concentration exceeds the display range value without exceeding 9990 ppm, the full scale display range value will be displayed but the actual gas reading at that time will be recorded when you press and release POWER ENTER. For example, if the display range is 1000 ppm but the gas level is 2300 ppm, the display will read 1000 ppm but the instrument will save a reading of 2300 ppm.
NOTE: If the gas concentration exceeds the display range without exceeding 9990 ppm, the full scale display range value will be displayed but the actual gas reading at that time will be recorded when you press and release POWER ENTER. For example, if the display range is 1000 ppm but the gas level is 2300 ppm, the display will read 1000 ppm but the instrument will save a reading of 2300 ppm.
3. If no snap logs have been performed, the following screen will appear. Press and release the DISPLAY (ADJ) button to return to Leak Check Mode. NO DATA 4. If snap logs have been performed, the following screen will appear. LEAK CK MODE will appear in the upper left corner to indicate that the snap log was taken during Leak Check Mode Operation. LEAK CK MODE 2012 2 15 14:17 M009 This screen indicates the year, month, day, and time that the most recent snap log was taken.
5. To view the data in a snap log ID, press and release the POWER ENTER button. You can also go back and forth between the ID and data screens by pressing and releasing the POWER ENTER button.
Data Logging The Gas Tracer features the ability to log data to its internal memory and download it to a computer via the infrared communications port located just below the RESET SILENCE button. It logs bump test data, calibration data, and event data. No interval trend or alarm trend data is saved. NOTE: Although interval trend and alarm trend data are not saved, the Gas Tracer saves snap log data. For a description of the snap logging function, see “Snap Log Mode” on page 28.
Calibration Mode Calibration mode allows you to calibrate and bump test the PPM sensor. The optimum frequency of calibration depends heavily on how the Gas Tracer is used. For example, instruments used daily may need to be calibrated weekly or monthly, while instruments that are used only a few times a year may need to be calibrated before each use. Typical calibration frequencies range from monthly to quarterly. You can program the Gas Tracer to notify you when it is due for calibration.
3. With the unit on, perform a fresh air adjust by pressing and holding the AIR▲ button. The display prompts you to hold the AIR▲ button. MAINTENANCE AIr CAL HOLD AIR 4. Continue to hold the AIR▲ button until the display prompts you to release it. The Gas Tracer will set the fresh air reading. 5. Install the demand flow regulator onto the calibration cylinder. 6. Connect the sample tubing to the demand flow regulator.
To return to normal operation, press and release the RESET SILENCE button. You may then try to reenter Calibration Mode. MAINTENANCE will appear along the top of the screen once you have entered Calibration Mode. The first item in the calibration menu, AIR CAL, displays. MAINTENANCE AIR CAL The recommended calibration sequence for a quarterly calibration is WET fresh air adjustment, WET span adjustment.
1. If you did not perform a fresh air adjustment while in Leak Check Mode, you must perform one before performing an auto calibration, a single calibration, or a bump test. MAINTENANCE AIR CAL 2. Press and release the POWER ENTER button to enter the AIR CAL menu item. MAINTENANCE WET You will be prompted to choose between WET and DRY. 3. Use the AIR▲ or (SHIFT)▼ buttons to display the WET setting and press and release the POWER ENTER button.
5. Hold down the AIR▲ button. The unit will prompt you to continue holding the AIR▲ button. MAINTENANCE AIr CAL HOLD AIR 6. When the unit prompts you to release the AIR▲ button, release it. The instrument will perform a fresh air adjustment on the ppm sensor and return you to the AIR CAL menu item. Performing a Dry Fresh Air Adjustment This section describes how to perform a fresh air adjustment on the PPM combustible gas sensor using the DRY setting.
2. Press and release the POWER ENTER button to enter the AIR CAL menu item. MAINTENANCE WET You will be prompted to choose between WET and DRY. 3. Use the AIR▲ or (SHIFT)▼ buttons to display the DRY setting and press and release the POWER ENTER button. The unit will display the current fresh air reading and prompt you to push the AIR▲ button. Do not press the AIR▲ button at this time. MAINTENANCE 50 CH4 ppm PUSH AIR 4. Install the demand flow regulator onto the zero air cylinder. 5.
sensor and return you to the AIR CAL menu item. 10.Disconnect the tubing from the probe. 11.Unscrew the demand flow regulator from the calibration cylinder. Performing an AUTO CAL This section describes how to calibrate the PPM combustible gas sensor using auto calibration. 1. Install the demand flow regulator onto the calibration cylinder. 2. Connect the humidifier to the demand flow regulator. 3. Install the hose and probe to the Gas Tracer. 4.
8. To adjust the value on the screen, hold down the (SHIFT)▼ button, then press the DISPLAY(ADJ) button and release both. The calibration gas value turns into three dashes. MAINTENANCE CH4 --- ppm AUTO CAL 9. Press and release the POWER ENTER button. The sensor’s calibration gas value will flash. 10.If necessary, use the AIR▲ and (SHIFT)▼ buttons to set the correct calibration gas value. 11.Press and release the POWER ENTER button to save the change. 12.
indicates that the ppm sensor failed to calibrate. MAINTENANCE CH4 ppm FAIL The buzzer and alarm lights activate. Press and release the RESET SILENCE button after the buzzer and lights stop to reset the alarm and return to the AUTO CAL menu item. Attempt to calibrate again. If the failure continues, investigate the cause. See “Troubleshooting” on page 82. 16.Disconnect the humidifier from the probe. NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself.
be replaced by 3 dashes. MAINTENANCE CH4 --- ppm ONE CAL 7. Press and release the POWER ENTER button. The single calibration screen displays. The gas reading flashes. MAINTENANCE CH4 0 ppm ONE CAL 8. Connect the humidifier from the demand flow regulator to the rigid tube on the probe. Allow the calibration gas to flow for two minutes. 9. If necessary, use the AIR▲ and (SHIFT)▼ buttons to adjust the reading to match the concentration listed on the calibration cylinder.
Performing a Bump Test NOTE: The BUMP DSP menu item in Maintenance Mode is factory set to OFF. The BUMP menu item will not appear unless BUMP DSP is set to ON. See “Turning the Bump Test Function On or Off” on page 68 for instructions. NOTE: The Gas Tracer uses parameters defined in the BUMP--SET menu item of Maintenance Mode while performing a bump test. To view or update these parameters, see “Updating the Bump Test Parameters” on page 69. 1.
7. Before proceeding, confirm that the bump test gas value is the same as the concentration in the calibration cylinder. If it is not, adjust the bump test gas value by entering the AUTO CAL menu item, changing the value there, and reentering the BUMP menu. 8. Connect the humidifier from the demand flow regulator to the rigid tube on the probe then quickly press and release the POWER ENTER button. The unit will begin counting down from 30. 9.
to investigate the cause of the failure and replace the failed sensor if necessary. • Disconnect the humidifier from the probe. NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself. 10.When AUTO CAL in the BUMP--SET menu item in Maintenance Mode is set to ON: If the ppm combustible sensor passes the bump test, • The following screen appears: MAINTENANCE CH4 P ppm BUMP • To view the bump test gas reading press the AIR▲ or (SHIFT)▼ button.
NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself. If the ppm combustible sensor fails the bump test, • The instrument will beep and a calibration is immediately and automatically started. Continue to apply the calibration gas. CAL on the bottom left of the screen will alternate with APPLY. The calibration time will begin to countdown in seconds in the lower right of the screen.
MAINTENANCE 25 CH4 ppm BUMP/ MAINTENANCE CH4 950 ppm /CAL • To return to the BUMP screen, press POWER ENTER at any time. If the sensor fails calibration, the buzzer will sound a double pulsing tone until you press and release the POWER ENTER button. MAINTENANCE BUMP • Disconnect the humidifier from the probe. NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself. 11.Unscrew the demand flow regulator from the calibration cylinder. 12.
Chapter 4: Maintenance Mode Overview This chapter describes the Gas Tracer in Maintenance Mode.
• turn the ID display function on or off • update the backlight settings • turn the autozero function on or off • turn the demand zero function on or off • update the Leak Check/Bar Hole Mode setting • update the bar hole sampling time • view the instrument’s firmware version and checksum information • turn the password function on or off and set the password • set the low flow alarm The Gas Tracer is factory-set to suit most applications.
2. Press and hold the AIR▲ and (SHIFT)▼ buttons, then press and hold the POWER ENTER button. When you hear a beep, release the buttons. The unit will prompt you for a password. MAINTENANCE 0000 PASSWORD 3. Enter the password by using the AIR▲ and (SHIFT)▼ buttons to select each password number and then pressing and releasing POWER ENTER to enter it and move on to the next one. To go back a number, press and release the RESET SILENCE button.
6. Use the AIR▲ or (SHIFT)▼ button to move through the menu item screens. Updating the Date and Time Settings 1. Use the AIR▲ or (SHIFT)▼ buttons to display the DATE menu item. MAINTENANCE DATE Press and release the POWER ENTER button. The date and time will be displayed with the year flashing. MAINTENANCE 2011 4 23 22:37 DATE 2. Use the AIR▲ or (SHIFT)▼ button to display the desired year. 3. Press and release the POWER ENTER button to save the setting. The month setting flashes. 4.
Performing a Bump Test The bump menu item is not functionally available in the Gas Tracer but will still appear in the Maintenance Mode menu. Calibrating and Bump Testing the PPM Combustible Sensor The PPM sensor in the Gas Tracer cannot be calibrated using the AUTO CAL or ONE CAL menu items in the main menu or bump tested using the BUMP menu item in the main menu. The PPM CAL menu item must be used.
tube is appropriate for a quarterly calibration. NOTE: It is recommended that you perform a fresh air adjust on the ppm sensor using a zero air cylinder and the DRY setting once every 6 months to maintain the accuracy of the ppm combustible gas reading. When performing a DRY fresh air adjustment, be sure to not use the humidifier tube. See “Performing a Dry Fresh Air Adjustment” on page 56 for instructions to perform a dry fresh air adjustment. 1.
NOTE: If you have just performed a DRY fresh air adjustment, allow the Gas Tracer to sample fresh air for 2 minutes before continuing. MAINTENANCE 50 CH4 ppm PUSH AIR 4. Be sure the Gas Tracer is in a fresh air environment. 5. Hold down the AIR▲ button. The unit will prompt you to continue holding the AIR▲ button. MAINTENANCE AIr CAL HOLD AIR 6. When the unit prompts you to release the AIR▲ button, release it.
1. Once the warm up is complete, you will be in PPM Cal Mode and AIR CAL will be displayed. You must perform a fresh air adjust before performing an auto calibration, a single calibration, or a bump test. MAINTENANCE AIR CAL 2. Press and release the POWER ENTER button to enter the AIR CAL menu item. MAINTENANCE WET You will be prompted to choose between WET and DRY. 3. Use the AIR▲ or (SHIFT)▼ buttons to display the DRY setting and press and release the POWER ENTER button.
8. Hold down the AIR▲ button. The unit will prompt you to continue holding the AIR▲ button. MAINTENANCE AIr CAL HOLD AIR 9. When the unit prompts you to release the AIR▲ button, release it. The instrument will perform a fresh air adjustment on the ppm sensor and return you to the AIR CAL menu item. 10.Disconnect the tubing from the probe. 11.Unscrew the demand flow regulator from the calibration cylinder.
7. The gas concentration displayed in the calibration value screen must match the gas concentration listed on the calibration cylinder. If the concentration matches, go to step 13. If the concentration does not match, continue with step 8. 8. To adjust the value on the screen, hold down the (SHIFT)▼ button, then press the DISPLAY(ADJ) button and release both. The calibration gas value turns into three dashes. MAINTENANCE CH4 --- ppm AUTO CAL 9. Press and release the POWER ENTER button.
bottom of the screen, then the AUTO CAL menu item displays. If the ppm sensor cannot calibrate to the proper value, FAIL displays along the bottom of the screen and the Gas Tracer indicates that the ppm sensor failed to calibrate. MAINTENANCE CH4 ppm FAIL The buzzer and alarm lights activate. Press and release the RESET SILENCE button after the buzzer and lights stop to reset the alarm and return to the AUTO CAL menu item. Attempt to calibrate again. If the failure continues, investigate the cause.
5. You will be prompted to choose between WET and DRY. Use the WET setting. NOTE: The DRY setting in ONE CAL is for factory use only. Do not perform a calibration in ONE CAL using the DRY setting. 6. Use the AIR▲ or (SHIFT)▼ buttons to display the WET setting and press and release the POWER ENTER button. The gas reading will be replaced by 3 dashes. MAINTENANCE CH4 --- ppm ONE CAL 7. Press and release the POWER ENTER button. The single calibration screen displays. The gas reading flashes.
NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself. 12.Unscrew the demand flow regulator from the calibration cylinder. 13.Use the (SHIFT)▼ button to navigate to the ESCAPE menu item, then press and release the POWER ENTER button to return to the PPM CAL menu in Calibration Mode. 14.Use the (SHIFT)▼ button to navigate to the NORMAL menu item, then press and release the POWER ENTER button to return to Measuring Mode.
press and release the POWER ENTER button. The bump test gas value will be displayed. MAINTENANCE CH4 1000 BUMP ppm 30 7. Before proceeding, confirm that the bump test gas value is the same as the concentration in the calibration cylinder. If it is not, adjust the bump test gas value by entering the AUTO CAL menu item in the PPM CAL menu, changing the value there, and reentering the BUMP menu. 8.
• To view the bump test gas reading press the AIR▲ or (SHIFT)▼ button. You can scroll between the bump test results and the bump test gas reading with the AIR▲ or (SHIFT)▼ button. MAINTENANCE CH4 1000 ppm BUMP • To return to the BUMP screen in Calibration Mode, press POWER ENTER. MAINTENANCE BUMP If the sensor fails the bump test, see “Troubleshooting” on page 82 to investigate the cause of the failure and replace the failed sensor if necessary. • Disconnect the humidifier from the probe.
• To view the bump test gas reading press the AIR▲ or (SHIFT)▼ button. You can scroll between the bump test results and the bump test gas reading with the AIR▲ or (SHIFT)▼ button. MAINTENANCE CH4 1000 ppm BUMP • To return to the BUMP screen in PPM CAL, press POWER ENTER. MAINTENANCE BUMP • Disconnect the humidifier from the probe. NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself.
If the ppm combustible sensor fails the bump test, • The instrument will beep and a calibration is immediately and automatically started. Continue to apply the calibration gas. CAL on the bottom left of the screen will alternate with APPLY. The calibration time will begin to countdown in seconds in the lower right of the screen.
MAINTENANCE CH4 950 ppm /CAL • To return to the BUMP screen in PPM CAL, press POWER ENTER at any time. If the sensor fails calibration, the buzzer will sound a double pulsing tone until you press and release the POWER ENTER button. MAINTENANCE BUMP • Disconnect the humidifier from the probe. NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself. 11.Unscrew the demand flow regulator from the calibration cylinder. 12.
Updating the Alarm Silence Setting The Alarm Silence Setting does not have any effect on the operation of the Gas Tracer. Updating the Data Log Interval Setting The Gas Tracer does not log operational data. The Data Log Interval Setting has no effect on the Gas Tracer. Updating the Alarm Point Settings The ALARM--P menu item is not functionally available in the Gas Tracer but will still appear in the Maintenance Mode menu.
4. Press and release the POWER ENTER button to save the setting and return to the main menu. Turning the Pump Off Screen On or Off The POFF DSP menu item does not have any effect on the Gas Tracer. Updating the Bump Test Parameters The BUMP--SET menu item is used to adjust the bump test parameters. NOTE: If the BUMP DSP menu item is set to OFF, this menu item does not appear. 1. Use the AIR▲ or (SHIFT)▼ buttons to display the BUMP--SET menu item. MAINTENANCE BUMP--SET 2.
increments are 30, 45, 60, and 90 seconds. Once a value is selected, press and release the POWER ENTER button to save it. The value will stop blinking. 4. To update the bump test tolerance, use the (SHIFT)▼ button to scroll to the CHECK value. The factory setting is 30%. This is the bump test tolerance value and is represented as a percentage. It is the percentage that the bump test reading can differ from the actual gas concentration. If the bump test reading differs more, the bump test will fail.
Updating the Confirmation Beep Setting With BEEP. SET set to ON, the Gas Tracer beeps once every 5 minutes to verify that it is operating. With BEEP. SET set to OFF (factory setting), the Gas Tracer does not sound a confirmation beep. 1. Use the AIR▲ or (SHIFT)▼ buttons to display the BEEP. SET menu item. Press and release the POWER ENTER button. The screen will indicate the current setting. MAINTENANCE On BEEP. SET 2. Use the AIR▲ or (SHIFT)▼ button to display the desired setting. 3.
Tip: Press and hold the AIR▲ or (SHIFT)▼ button to rapidly scroll through the settings. 3. Press and release the POWER ENTER button to save the setting and return to the main menu. Updating the Calibration Reminder Setting With CL RMNDR set to ON, the Gas Tracer will give an indication at start up if it is due for calibration. The type of indication will depend on the CL EXPRD setting (see below).
With CL EXPRD set to NO EFFECT, no confirmation during startup or calibration is required to use the Gas Tracer if calibration is overdue. 1. Use the AIR▲ or (SHIFT)▼ buttons to display the CL EXPRD menu item. Press and release the POWER ENTER button. The screen will indicate the current setting. MAINTENANCE CAL SEL CONFIRM 2. Use the AIR▲ or (SHIFT) ▼ button to display the desired setting along the bottom of the screen. 3.
3. Press and release the POWER ENTER button to save the setting and return to the main menu. Updating the Bump Test Interval The BP INTVL setting defines the amount of time between bump tests. The minimum setting is 0 days and the maximum setting is 30 days. The factory setting is 30 days. NOTE: If the BUMP DSP menu item is set to OFF, this menu item does not appear. 1. Use the AIR▲ or (SHIFT)▼ buttons to display the BP INTVL menu item. Press and release the POWER ENTER button.
1. Use the AIR▲ or (SHIFT)▼ buttons to display the BP RMNDR menu item. Press and release the POWER ENTER button. The screen will indicate the current setting. MAINTENANCE On BP RMNDR 2. Use the AIR▲ or (SHIFT)▼ button to display the desired setting. 3. Press and release the POWER ENTER button to save the setting and return to the main menu. Updating the Bump Test Expired Action Setting This item defines what indication is given during start up when a bump test is due and BP RMNDR is set to ON.
1. Use the AIR▲ or (SHIFT)▼ buttons to display the BP EXPRD menu item. Press and release the POWER ENTER button. The screen will indicate the current setting. MAINTENANCE tESt SEL CONFIRM 2. Use the AIR▲ or (SHIFT) ▼ button to display the desired setting along the bottom of the screen. 3. Press and release the POWER ENTER button to save the setting and return to the main menu. Updating the Bump Test Check Setting This item setting defines which sensors are used to update the bump test reminder screen.
Turning the ID Display Function On or Off With ID DISP set to ON, the User ID Screen and Station ID Screens display during start up and in Display Mode. The ID’s can be updated in Display Mode. With ID DISP set to OFF (factory setting), the User ID Screen and Station ID Screens do not display during start up or in Display Mode. 1. Use the AIR▲ or (SHIFT)▼ buttons to display the ID DISP menu item. Press and release the POWER ENTER button. The screen will indicate the current setting.
3. Press and release the POWER ENTER button to save the setting and return to the main menu. Updating the Autozero Function With AUTO.ZERO turned ON, the Gas Tracer will automatically perform a fresh air adjust when it is turned on. With AUTO.ZERO function turned OFF (factory setting), this does not occur. WARNING: If you turn on the autozero function, you must ensure that the unit is in a fresh air environment when it is turned on. 1. Use the AIR▲ or (SHIFT)▼ buttons to display the AUTO.ZERO menu item.
2. Use the AIR▲ or (SHIFT) ▼ button to display the desired setting. 3. Press and release the POWER ENTER button to save the setting and return to the main menu. Updating the Leak Check/Bar Hole Mode Setting The L./B. MODE setting does not have any effect on the operation of the Gas Tracer. It will always automatically turn on in Leak Check Mode.
NOTE: A password is always required to enter Maintenance Mode even if PASSWORD is turned OFF. You may change the factory set password by turning PASSWORD ON and entering a new password when prompted for it. 1. Use the AIR▲ or (SHIFT)▼ buttons to display the PASSWORD menu item. Press and release the POWER ENTER button. The screen indicates the current setting. MAINTENANCE On PASSWORD 2. Use the AIR▲ or (SHIFT)▼ button to display the desired setting. 3.
1. Use the AIR▲ or (SHIFT)▼ buttons to display the FLOW ADJ menu item. Press and release the POWER ENTER button. The pump will turn off and the screen will display values that reflect the pump’s current draw. MAINTENANCE 45 % 1496 FLOW ADJ 2. Use the AIR▲ or (SHIFT)▼ buttons to get a reading of approximately 1500 on the bottom value. When you have adjusted the value as close as you can, press and release the POWER ENTER button. 3. The pump will turn on and two new values will be displayed.
Chapter 5: Gas Tracer Maintenance Overview This chapter describes troubleshooting procedures for the Gas Tracer. It also includes procedures for recharging the battery pack (rechargeable version), replacing the alkaline batteries (alkaline version), and replacing various consumable parts. WARNING: RKI Instruments, Inc. recommends that service, calibration, and repair of RKI instruments be performed by personnel properly trained for this work.
Table 5: Troubleshooting the Gas Tracer Symptoms Probable Causes Recommended Action • Display indicates “FAIL SYSTEM” during startup along with an error code. • A circuit fault has occurred on one of the PCB’s. 1. If the error code is 031, indicating a FLASH memory failure, press and release the RESET SILENCE button to continue to measuring mode keeping in mind that there will be no datalogging function. 2. If the error code is anything else, the instrument cannot be used. 3.
Table 5: Troubleshooting the Gas Tracer Probable Causes Recommended Action • The unit indicates flow failure and does not recover when RESET SILENCE is pressed and released. • The cotton filter in the probe or filter holder is dirty and clogged. • The sample hose has a kink or obstruction. • The hydrophobic filter disks or wire mesh disk are dirty and clogged. • The pump is malfunctioning. 1. Change the cotton filter in the probe or filter holder. 2.
Replacing or Recharging the Batteries WARNING: To prevent ignition of a hazardous atmosphere, batteries must only be changed in an area known to be nonhazardous. Replace the batteries when the battery icon indicates that the unit is in low battery warning. When in low battery warning, the lowest battery level indication bar is displayed in the battery icon on the LCD, and it will be flashing.
Replacing the Lithium Ion Battery Pack NOTE: Use Procell PC 1500 alkaline batteries, Duracell MN 1500 alkaline batteries, or RKI Instruments lithium ion battery pack 49-1615RK to maintain the CSA classification of the Gas Tracer. Use of other batteries will void the CSA classification and may void the warranty. 1. Turn off the Gas Tracer. WARNING: Do not remove the battery pack while the Gas Tracer is on. 2.
Recharging the Lithium Ion Battery Pack in the Instrument CAUTION: To be used only with lithium ion battery pack p/n 49-1615RK. Charge only with RKI charger model BC-2009, p/n 49-2180RK, or RKI charger model BC-2009DC, p/n 49-2181RK. Use of other rechargeable batteries or chargers or charging of other rechargeable batteries in the Gas Tracer will void the warranty. 1. Make sure the Gas Tracer is off. 2. Confirm that the adapter’s DC output cord is plugged into the charger. 3.
If using a DC powered charging station, plug the 12 VDC vehicle plug adapter into a vehicle’s 12 VDC power socket. Power Supply Jack DC Adapter To Vehicle 12 VDC Power Socket Charge LED DC Powered Charging Station Figure 16: Connecting the Charging Station’s DC Adapter The construction of the charging stations allows them to be chained together but a separate adapter must be used for each charging station. One adapter will not operate more than one charging station. 4.
Red Charging LED Figure 17: Putting the Gas Tracer into the Charging Station 5. When a full charge has been reached, approximately 4 hours, the red LED on the charging station will turn off. Remove the Gas Tracer from the charging station and unplug the charging station’s power cord from the AC outlet. Recharging the Lithium Ion Battery Pack Out of the Instrument The lithium ion battery pack may be charged using the charging station while it is out of the Gas Tracer.
3. If using an AC powered charging station, plug the AC adapter into an electrical outlet.
If using a DC powered charging station, plug the 12 VDC vehicle plug adapter into a vehicle’s 12 VDC power socket. Power Supply Jack DC Adapter To Vehicle 12 VDC Power Socket Charge LED DC Powered Charging Station Figure 19: Connecting the Charging Station’s DC Adapter The construction of the charging stations allows them to be chained together but a separate adapter must be used for each charging station. One adapter will not operate more than one charging station.
4. Insert the battery pack into the charging station as shown in Figure 20 below so that the metal contacts on the back of the battery pack come into contact with the metal contacts in the charging station. When proper contact has been made, the red LED on the charging station will turn on. Battery Pack CHARGE GX-2012 OFF POWER BUMP CAL. SDM-2012 EDIT ENTER COPY 1SEC ON 3SEC OFF Figure 20: Putting the Battery Pack into the Charging Station 5.
dummy sensor installed. 7. Carefully insert the replacement sensor in the correct socket. Sensor Gasket Exhaust Flow Chamber HC VOL HC LEL Knob O2 HC PPM CO PPM Combustible Sensor Figure 21: Replacing a Sensor CAUTION: When replacing the ppm sensor, verify that the sensor is properly aligned with its socket before inserting it into the socket. The ppm combustible sensor has two non-polarized contacts which must line up with the contacts in its socket.
12.Place the belt clip into position and tighten the three screws retaining it. 13.Start up the Gas Tracer by pressing and briefly holding the POWER ENTER button. 14.Calibrate the new sensor as described in “Calibration Mode” on page 35. You must perform a DRY air adjustment, a WET air adjustment, and a WET span adjustment. Replacing the Hydrophobic Disk Filter, Cotton Filter, and Wire Mesh Disk 1. Verify that the Gas Tracer is off. 2. Locate the clear plastic filter holder at the top of the Gas Tracer. 3.
6. Remove the old hydrophobic filters and/or wire mesh disk from the gasket. A hydrophobic filter is located on either side of the wire mesh disk. 7. Install the new hydrophobic filters and/or wire mesh disk making sure a hydrophobic filter is located on each side of the wire mesh disk. 8. Reinstall the gasket with the parts into the case. Ensure that the installation stub is lined up with the pump intake in the filter chamber. 9. Reinstall the filter holder with the cotton dust filter.
Table 6: Parts List (cont.
Appendix A: Calibrating or Bump Testing with a Sample Bag Overview The Gas Tracer can be calibrated or bump tested with a gas bag calibration kit instead of a demand flow regulator kit. Appendix A describes how to use a sample bag calibration kit to calibrate and bump test the Gas Tracer. A parts list at the end of this appendix lists spare parts for the calibration kit.
To calibrate or bump test the Gas Tracer, you will need: • Known calibrating sample of ppm methane gas. • A gas collection bag with hose clamp • A 0.5 LPM fixed-flow regulator or dispensing valve • Non-absorbent tubing • 6 inch humidifier tube Preparing for Calibration or Bump Test Perform the following tasks prior to performing a calibration or a bump test.
2. Connect the other end of the tubing to the regulator’s or dispensing valve’s hose barb fitting. NOTE: Do not use the 6 inch humidifier tube at this point. 3. Fill the gas collection bag by screwing the fixed flow regulator onto the calibration cylinder or by screwing the dispensing valve onto the calibration cylinder and turning the knob counterclockwise. NOTE: If the regulator has no on/off knob, then gas will begin to flow at 0.5 LPM as soon as the regulator is connected to the cylinder. 4.
on page 79. If you enter an incorrect password, an error screen will display. Err PASSWORD To return to normal operation, press and release the RESET SILENCE button. You may then try to reenter Calibration Mode. MAINTENANCE will appear along the top of the screen once you have entered Calibration Mode. The first item in the calibration menu, AIR CAL, displays. MAINTENANCE AIR CAL The recommended calibration sequence for a quarterly calibration is WET fresh air adjustment, WET span adjustment.
1. After entering Cal Mode, the AIR CAL menu item will be displayed. You must perform a fresh air adjust before performing an auto calibration, a single calibration, or a bump test. MAINTENANCE AIR CAL 2. If the instrument is not in a fresh air environment, fill the gas bag with zero air as described in “Filling the Gas Bag” on page 98. 3. Press and release the POWER ENTER button to enter the AIR CAL menu item.
instrument is not in a fresh air environment, connect a gas bag with zero air to the rigid tube on the probe using the 6 inch humidifier tube and open the clamp allowing the instrument to draw zero air for 2 minutes. 6. Hold down the AIR▲ button. The unit will prompt you to continue holding the AIR▲ button. MAINTENANCE AIr CAL HOLD AIR 7. When the unit prompts you to release the AIR▲ button, release it.
1. After entering Calibration Mode, the AIR CAL menu item will be displayed. You must perform a fresh air adjust before performing an auto calibration, a single calibration, or a bump test. MAINTENANCE AIR CAL 2. Fill the gas bag with zero air as described in “Filling the Gas Bag” on page 98. 3. Press and release the POWER ENTER button to enter the AIR CAL menu item. MAINTENANCE WET You will be prompted to choose between WET and DRY. 4.
6. Hold down the AIR▲ button. The unit will prompt you to continue holding the AIR▲ button. MAINTENANCE AIr CAL HOLD AIR 7. When the unit prompts you to release the AIR▲ button, release it. The instrument will perform a fresh air adjustment on the ppm sensor and return you to the AIR CAL menu item. 8. Disconnect the tubing from the probe. Performing an Auto Calibration This section describes how to calibrate the PPM combustible gas sensor using auto calibration. 1.
If the concentration matches, go to step 11. If the concentration does not match, continue with step 6. 6. To adjust the value on the screen, hold down the (SHIFT)▼ button, then press the DISPLAY(ADJ) button and release both. The calibration gas value turns into three dashes. MAINTENANCE CH4 --- ppm AUTO CAL 7. Press and release the POWER ENTER button. The sensor’s calibration gas value will flash. 8. If necessary, use the AIR▲ and (SHIFT)▼ buttons to set the correct calibration gas value. 9.
If the ppm sensor cannot calibrate to the proper value, FAIL displays along the bottom of the screen and the Gas Tracer indicates that the ppm sensor failed to calibrate. MAINTENANCE CH4 ppm FAIL The buzzer and alarm lights activate. Press and release the RESET SILENCE button after the buzzer and lights stop to reset the alarm and return to the AUTO CAL menu item. Attempt to calibrate again. If the failure continues, investigate the cause. See “Troubleshooting” on page 82. 14.
4. Use the AIR▲ or (SHIFT)▼ buttons to display the WET setting and press and release the POWER ENTER button. The gas reading will be replaced by 3 dashes. MAINTENANCE CH4 --- ppm ONE CAL 5. Press and release the POWER ENTER button. The single calibration screen displays for the sensor you selected. The gas reading flashes. MAINTENANCE CH4 0 ppm ONE CAL 6. Connect the humidifier from the gas bag to the rigid tube on the probe. Allow the calibration gas to flow for two minutes. 7.
Performing a Bump Test This section describes how to bump test the PPM combustible gas sensor. NOTE: The BUMP DSP menu item in Maintenance Mode is factory set to OFF. The BUMP menu item will not appear unless BUMP DSP is set to ON. See “Turning the Bump Test Function On or Off” on page 68 for instructions. NOTE: The Gas Tracer uses parameters defined in the BUMP--SET menu item of Maintenance Mode while performing a bump test.
5. Before proceeding, confirm that the bump test gas value is the same as the concentration in the calibration cylinder. If it is not, adjust the bump test gas value by entering the AUTO CAL menu item, changing the value there, and reentering the BUMP menu. 6. Connect the humidifier from the gas bag to the rigid tube on the probe and quickly press and release the POWER ENTER button. The unit will begin counting down from 30. 7.
• To return to the BUMP screen in Calibration Mode, press POWER ENTER. MAINTENANCE BUMP If the sensor fails the bump test, see “Troubleshooting” on page 82 to investigate the cause of the failure and replace the failed sensor if necessary. • Disconnect the humidifier from the probe. NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself. 8.
• To return to the BUMP screen, press POWER ENTER. MAINTENANCE BUMP • Disconnect the humidifier from the probe. NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself. If the ppm combustible sensor fails the bump test, • The instrument will beep and a calibration is immediately and automatically started. Continue to apply the calibration gas. CAL on the bottom left of the screen will alternate with APPLY.
• At the end of the calibration, the instrument displays the results from both the bump test and the calibration. Use the AIR▲ or (SHIFT)▼ button to scroll between the calibration/ bump test results, the bump test gas reading, and the calibration gas reading.
• To return to the BUMP screen, press POWER ENTER at any time. If the sensor fails calibration, the buzzer will sound a double pulsing tone until you press and release the POWER ENTER button. MAINTENANCE BUMP • Disconnect the humidifier from the probe. NOTE: Grasp the humidifier tube assembly by the clear tubing at the end, not the humidifier tube itself. 9. Use the (SHIFT)▼ button to navigate to the ESCAPE menu item, then press and release the POWER ENTER button to return to Measuring Mode.
