RKI Instruments GP-03 Operator's Manual
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RKI Instruments GP-03 Operator's Manual

03 series
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03 Series:
GP-03 Version
Operator's Manual
Part Number: 71-0303
Revision: B
Released: 4/14/17
www.rkiinstruments.com

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Summary of Contents for RKI Instruments GP-03

  • Page 1 03 Series: GP-03 Version Operator’s Manual Part Number: 71-0303 Revision: B Released: 4/14/17 www.rkiinstruments.com...
  • Page 2 Typical calibration frequencies for most applications are between 1 and 3 months, but can be required more often or less often based on your usage. GP-03 Operator’s Manual...
  • Page 3 Warranty RKI Instruments, Inc. warrants the GP-03 Single Gas Monitor sold by us to be free from defects in materials, workmanship, and performance for a period of two (2) years from the date of shipment from RKI Instruments, Inc. This includes the instrument and the original sensor. Replacement parts are warranted for one (1) year from the date of their shipment from RKI Instruments, Inc.

  • Page 4: Table Of Contents

    Turning Off the GP-03 ........
  • Page 5 Parts List............66 WARNING: Understand this manual before operating the GP-03.

  • Page 6: Introduction

    (e.g., methane, CH ) as a percentage of LEL (lower explosive limit). The GP-03’s compact size and easy-to-use design make it ideally suited for a wide range of applications, including sewage treatment plants, tunnels, hazardous waste sites, petrochemical facilities, oil fields, mines, and chemical plants.

  • Page 7: Specifications

    Specifications Table 1: GP-03 Specifications Target Gas Combustible Gas, Methane (CH ) Calibration Standard* Detection Range 0 to 100% LEL Display Increment 1% LEL Detection Principle Catalytic Combustion Method Alarm Points • Low Alarm: 10% LEL • High Alarm: 50% LEL •...
  • Page 8 Operating Temp. & -20°C to +50°C, below 90% RH (non condensing) Humidity *The GP-03 is also available set up for general hydrocarbons and calibrated to a combustible gas other than methane, such as isobutane. Consult RKI Instruments, Inc. for further information.

  • Page 9: Description

    Figure 1: Components of the GP-03 Case The GP-03’s sturdy, high-impact plastic case is blue and consists of a front case and a rear case. The case is suitable for use in many environmental conditions, indoors and out. The unit is dust proof and weather resistant.

  • Page 10: Sensor Gasket, Sensor Membrane, And H

    S Filter Disk” on page 64 for sensor membrane replacement instructions. The H S filter disk is not installed in the GP-03 as shipped from the factory. It can be installed to protect the combustible gas sensor from H exposure if H S will be present in the monitoring area.

  • Page 11: Lcd

    Calibration Mode or Setup Mode. Alarm LED The GP-03 has one red alarm LED. It alerts you to gas, low battery, and sensor failure alarms. The alarm LED is located at the top of the front case beneath a clear lens.

  • Page 12: Buzzer

    IrDA protocol. A computer’s infrared port or an IrDA/USB cable connected to a computer’s USB port can be used to download data saved by the GP-03 to a computer using the 03 Series Data Logger Management Program. See the 03 Series Data Logger Management Program operator’s manual for data logging and...

  • Page 13: Protective Rubber Boot

    être modifiés ou facturés dans une zone connue comme non dangereuse. NOTE: Use of batteries not specified by RKI Instruments, Inc. will void the CSA classification and may void the warranty. See “Replacing or Recharging the Batteries” on page 60.

  • Page 14: Alligator & Belt Clips

    45 degree turns if necessary. Alligator Clip Closed Open Figure 3: Alligator Clip The belt clip is shown in Figure 4 below and is used to easily clip the GP-03 on a belt. Belt Clip Figure 4: Belt Clip 9 • Description...

  • Page 15: Start Up

    Start Up This section explains how to start up the GP-03 and to get it ready for operation. CAUTION: Before each day’s usage sensitivity must be tested on a known concentration of the combustible target gas, typically methane, equivalent to 25 - 50% of full scale. Accuracy must be within -0% to +20% of concentration.
  • Page 16 WARNING: You must press either the POWER MODE or AIR button to continue. If you do not press a button, the buzzer will continue to beep and the LED will continue to flash for 6 seconds every 5 seconds. 11 • Start Up GP-03 Operator’s Manual...
  • Page 17 E--CAL menu item in Calibration Mode. The above screen will remain on the display until the unit is either turned off or Calibration Mode is entered. The GP-03 cannot be used until a complete calibration has been performed either by selecting A-- CAL, E--CAL, or M--CAL in the Calibration Mode menu.
  • Page 18 If the unit is due for bump testing and Bump Test Limit Check is set to Confirm to use (factory setting), then the following screen sequence will occur. BUMP teSt teSt teSt MODE BUMP BUMP teSt teSt teSt 13 • Start Up GP-03 Operator’s Manual...
  • Page 19 If you do not perform a successful bump test, the buzzer will continue to beep and the LED will continue to flash for 6 seconds every 5 seconds and the unit will not enter normal operation. GP-03 Operator’s Manual Start Up • 14...
  • Page 20 BUMP NEXT 8. The Date/Time Screen appears for a few seconds. 2014 1.31 8:20 This screen displays the current date and time. 9. The Battery Voltage Screen appears for a few seconds. bAtt 15 • Start Up GP-03 Operator’s Manual...
  • Page 21 • Warning setpoint (low gas alarm) • Alarm setpoint (high gas alarm) 11. If the GP-03 experiences a sensor failure during start up, the following screen will appear. SENSOR FAIL The instrument cannot be used if a sensor failure occurs. Replace the failed sensor.

  • Page 22: Performing A Fresh Air Adjustment

    13. The GP-03 is now operating in Measuring Mode and monitoring for gas. The Normal Operation Screen appears and the instrument beeps once. %LEL The gas concentration of the target gas is displayed along with the battery charge level in the lower left corner. The heart symbol displayed in the upper right corner flashes while the instrument is functioning properly.

  • Page 23: Turning Off The Gp-03

    NOTE: If Power Off Password Protection is turned On (factory setting is Off) using the 03 Series User Setup Program, a password is required to turn the GP-03 off. When the password screen appears, adjust each digit with the AIR button and press and release the POWER MODE button to move on to the next digit.
  • Page 24 The table below lists the conversion factors for several hydrocarbon gasses if the GP-03 is calibrated to methane. To use this table, multiply the display reading on the GP-03 by the factor in the appropriate row to obtain the actual gas concentration.

  • Page 25: Adjusting The Buzzer Volume

    S scrubber disk is used, then response to solvent gases such as IPA, toluene, or styrene will be slowed and decreased. If the GP-03 is to be used for solvent gas applications, do not install the H S scrubber disk.

  • Page 26: Display Mode

    To enter Display Mode, do the following: 1. Make sure the GP-03 is in the Measuring Mode Normal Operation screen. The GP-03 must be in the Normal Operation Screen for you to access Display Mode. 2. Press and release the POWER MODE button to enter Display Mode.

  • Page 27: Alarms

    03 after an alarm has occurred and how to respond to an alarm condition. Alarm Indications The GP-03 will sound the buzzer, flash its alarm light, and vibrate when the target gas concentration rises above the warning level. The GP-03 also sounds the buzzer, flashes its alarm light, and vibrates when the high level is reached.
  • Page 28 GP-03. (Or there • Back light turns on. • Vibrator pulses at could be a problem • ALRM appears same rate as alarm with the unit.)
  • Page 29 1. Follow your established procedure for an increasing combustible gas condition. 2. If your unit is set for latching alarms, reset the alarm using the POWER MODE button once the alarm condition has been cleared. GP-03 Operator’s Manual Operation • 24...
  • Page 30 2. Reset the alarm by pressing and releasing the POWER MODE button after the alarm condition has cleared. 3. Calibrate the GP-03 as described in “Calibration Mode” on page 28. 4. If the over range condition continues, replace the sensor as described in “Replacing the Sensor”...
  • Page 31 2. Attempt to change the date using the DATE menu item in Calibration Mode. See “Setting the Date and Time” on page 30. 3. If the date cannot be set correctly, contact RKI Instruments, Inc. as soon as possible. GP-03 Operator’s Manual...

  • Page 32: Data Logging

    Data Logging The GP-03 features the ability to log data to its internal memory and download it to a computer via the IrDA port on the top of the front case. It logs normal operation gas readings, alarm data, calibration data, and bump test data.

  • Page 33: Calibration Mode

    Calibration Mode. Although it will respond to gas in parts of AIR CAL, A--CAL., M--CAL., and BUMP, there are no gas alarm indications. 1. Take the GP-03 to a non-hazardous area and turn it off if it is on. GP-03 Operator’s Manual Calibration Mode • 28...
  • Page 34 START 7. At the START screen, press and release the POWER MODE button. The GP-03 will begin its start-up sequence. The Calibration Mode menu items are described below in the order in which they appear while moving through Calibration Mode.

  • Page 35: Setting The Date And Time

    Calibration Mode is the same as a fresh air adjustment in Normal Mode. The AIR menu item is available in Calibration Mode for convenience when performing a complete calibration. WARNING: Calibrate the GP-03 in a non-hazardous environment. GP-03 Operator’s Manual Calibration Mode • 30...

  • Page 36: Performing An Automatic Span Adjustment In A--Cal

    Performing an Automatic Span Adjustment in A--CAL Entering the A--CAL menu item allows you to perform an automatic span adjustment. A--CAL. Perform a span adjustment as part of a calibration after performing a fresh 31 • Calibration Mode GP-03 Operator’s Manual...
  • Page 37 Performing a span adjustment requires the use of a calibration kit. A calibration kit is available from RKI Instruments, Inc. for the GP-03 (see “Parts List” on page 66). You will need: • A gas cylinder with an appropriate concentration of the target gas CAUTION: Do not use a gas mix that includes H S to calibrate the GP-03.
  • Page 38 If you want to cancel the calibration, press and hold the AIR key for 2 seconds. The instrument will return to the A--CAL. Screen. If you hold the AIR key down longer than 2 seconds, the instrument will start scrolling through the Calibration Mode items. 33 • Calibration Mode GP-03 Operator’s Manual...
  • Page 39 5. Confirm that the regulator on/off knob is turned all the way clockwise (closed) and screw the calibration gas cylinder onto the regulator. 6. Push the calibration adapter onto the GP-03’s sensor face as shown in Figure 6. The calibration adapter secures itself to the instrument by latching on to two recesses in the instrument’s rear case.
  • Page 40 8. Allow the gas to flow for two minutes. 9. Press and release the POWER MODE button. 10. The GP-03 will attempt to make a span adjustment. 11. If the span adjustment is successful, the LCD will show the following screen before returning to the A--CAL screen.

  • Page 41: Performing An Easy Span Adjustment In E--Cal

    Perform a span adjustment as part of a calibration after performing a fresh air adjustment. Performing a span adjustment requires the use of a calibration kit. A calibration kit is available from RKI Instruments, Inc. (see “Parts List” on page 66). You will need: •...
  • Page 42 WARNING: Calibrate the GP-03 in a non-hazardous environment. 1. Before performing a span adjustment, perform a fresh air adjustment as described in “Performing a Fresh Air Adjustment” on page 30. 2. At the E--CAL screen, press and release the POWER MODE button. A screen appears that displays the calibration gas concentration that the GP-03 expects you to use.
  • Page 43 Regulator Calibration Tubing Calibration Adapter Figure 7: Calibration Kit Assembly 5. Confirm that the regulator on/off knob is turned all the way clockwise (closed) and screw the calibration gas cylinder onto the regulator. GP-03 Operator’s Manual Calibration Mode • 38...
  • Page 44 Step 12. See “Troubleshooting” on page 58 to investigate the cause of the issue. 9. At the end of the countdown, the GP-03 will attempt to make a span adjustment. 39 • Calibration Mode...
  • Page 45 12. Turn the regulator on/off knob clockwise to close it. 13. Remove the calibration adapter from the instrument. 14. Remove the regulator from the calibration gas cylinder. 15. Leave the regulator connected to the calibration adapter for convenience. GP-03 Operator’s Manual Calibration Mode • 40...

  • Page 46: Performing A Manual Span Adjustment In M--Cal

    Performing a span adjustment requires the use of a calibration kit. A calibration kit is available from RKI Instruments, Inc. for the GP-03 (see “Parts List” on page 66). The procedure below describes a span adjustment. You will need: •...
  • Page 47 Regulator Calibration Tubing Calibration Adapter Figure 9: Calibration Kit Assembly 4. Confirm that the regulator on/off knob is turned all the way clockwise (closed) and screw the calibration gas cylinder onto the regulator. GP-03 Operator’s Manual Calibration Mode • 42...
  • Page 48 9. Press and release the POWER MODE button. 10. The GP-03 will make the span adjustment and will return to the M--CAL. Screen. M--CAL.

  • Page 49: Performing A Bump Test In Bump

    BUMP Performing a bump test requires the use of a calibration kit. A calibration kit is available from RKI Instruments, Inc. for the GP-03 (see “Parts List”). You will need: •...
  • Page 50 “Performing a Fresh Air Adjustment” on page 30. 2. At the BUMP screen, press and release the POWER MODE button. A screen appears that displays the gas concentration that the GP-03 expects you to use. NOTE: The bump test gas concentration is the same as the A--CAL gas concentration.
  • Page 51 5. Push the calibration adapter onto the GP-03’s sensor face as shown in Figure 12. The calibration adapter secures itself to the instrument by latching on to two recesses in the instrument’s rear case. The rubber boot (if installed) does not need to be removed to install the adapter.
  • Page 52 Turn the regulator on/off knob clockwise to close it. 10. When Calibration After Bump Test Failed is set to On: If the instrument passes the bump test, • The following screen appears: BUMP 47 • Calibration Mode GP-03 Operator’s Manual...
  • Page 53 The bump test’s result is the first letter and the calibration’s result is the second letter. An “F” represents a failed test and a “P” represents a passed test. BUMP BUMP GP-03 Operator’s Manual Calibration Mode • 48...

  • Page 54: Viewing The Instrument's Firmware Version

    The ROM screen shows the firmware version that is loaded in the instrument and the firmware checksum. 1. At the ROM screen, press and release the POWER MODE button. 00028 - - - - 49 • Calibration Mode GP-03 Operator’s Manual...
  • Page 55 (00028 in this example) and the bottom line is the firmware checksum (FE7F in this example). 00028 FE7F 3. Press and release the POWER MODE button to return to the ROM screen. GP-03 Operator’s Manual Calibration Mode • 50...

  • Page 56: Setup Mode

    AIR CAL, A--CAL, and M--CAL, there are no gas alarm indications. 1. Take the GP-03 to a non-hazardous area and turn it off if it is on. 2. Press and hold the AIR button, then press and hold the POWER MODE button.
  • Page 57 Setup Mode or turn on the unit and proceed to Measuring Mode. NOTE: If you have forgotten your password, contact RKI Instruments, Inc. 5. If the PASS--W menu item is set to OFF, the DATE Screen is displayed.

  • Page 58: Setting The Date And Time In Date

    START 10. At the START screen, press and release the POWER MODE button. The GP-03 will begin its start-up sequence. The Setup Mode menu items are described below in the order in which they appear while moving through Setup Mode.

  • Page 59: Performing A Manual Span Adjustment In M--Cal

    M--CAL. Setting the Alarm Points Entering the ALM--P menu item allows you to set the alarm points. ALM--P Table 6 below lists the factory set alarm points for the GP-03. Table 6: Factory Set Alarm Points Warning Alarm...

  • Page 60: Adjusting The Bump Test Limit Check Setting

    CONF (factory setting) The user must press and release the AIR button to acknowledge that a bump test is due or press and release the POWER MODE button to perform a bump test before continuing with the warmup sequence. 55 • Setup Mode GP-03 Operator’s Manual...

  • Page 61: Setting The Password

    A screen will appear that shows the current password feature setting. PASS--W 2. Press and release the AIR button to change the displayed setting. When the desired setting is displayed, press and release the POWER MODE button to save the setting. GP-03 Operator’s Manual Setup Mode • 56...
  • Page 62 7. The next digit will begin flashing. 8. Repeat Step 5 through Step 7 until you have set all four of the digits. 9. When you save the last digit, the unit will return to the PASSWORD screen. PASS--W 57 • Setup Mode GP-03 Operator’s Manual...

  • Page 63: Maintenance

    Maintenance This section describes troubleshooting procedures for the GP-03. It also describes how to change the GP-03’s batteries, replace the sensor, replace the H S filter disk (if used), and replace the sensor membrane. WARNING: RKI Instruments, Inc. recommends that service, calibration, and repair of RKI instruments be performed by personnel properly trained for this work.
  • Page 64 2. Make sure the GP-03 has • The sample gas is been properly set up for not reaching the calibration. sensor because of 3. Verify that the calibration a bad connection.

  • Page 65: Replacing Or Recharging The Batteries

    NOTE: Use Duracell MN2400 or PC2400 or Eneloop BK-4MCC to maintain the CSA classification of the GP-03. Use of other batteries will void the CSA classification and may void the warranty. Do not mix old/new or different types of batteries.
  • Page 66 “Setting the Date and Time” on page 30. Once the date and time have been set, the instrument will begin its warmup sequence. If you do not set the date and time within 30 seconds, the instrument will automatically begin its warmup sequence. 61 • Maintenance GP-03 Operator’s Manual...

  • Page 67: Replacing The Sensor

    1. Remove the batteries from the GP-03 as described in Step 1 - Step 4 on page 60. 2. Install the Ni-MH batteries in the charger. See the battery charger’s operator’s manual for charging instructions.
  • Page 68 Rear Tabs Case Oxygen Sensor Sensor Sensor Oxygen Align Slots in H2S Sensor Not and CO Sensor Keyed with Tabs in Case Figure 16: Replacing the Sensor 63 • Maintenance GP-03 Operator’s Manual...

  • Page 69: Replacing The Sensor Membrane And H 2 S Filter Disk

    NOTE: An alligator or belt clip may be installed on the instrument but is not shown in the figures in this section. 1. Verify that the GP-03 is off. 2. Remove the rubber boot, if installed. 3. With a small Phillips screwdriver, carefully unscrew the four screws that attach the rear case to the front case.
  • Page 70 6. Turn the front case upside down so that the sensor gasket is visible. Front Case Sensor Membrane Charcoal Filter Charcoal Filter (CO-03 Only) (CO-03 Only) Sensor Gasket Sensor Gasket Rear Case Front Case, Inside View Figure 18: Replacing the Sensor Membrane and H2S Filter Disk 65 • Maintenance GP-03 Operator’s Manual...

  • Page 71: Parts List

    11. Turn the front case right side up and carefully secure it to the rear case using the screws you removed in Step 3. 12. Reinstall the rubber boot if it is being used. Parts List Table 6 lists replacement parts and accessories for the GP-03. Table 9: Parts List Part Number Description...
  • Page 72 103 liter steel cylinder 81-1146 Calibration adapter for GP-03 81-GP03 Calibration kit for GP-03 containing: one 103-liter steel gas cylinder (50 %LEL methane in air), regulator, calibration adapter, case, tubing 81-GP03-LV Calibration kit for GP-03 containing: one 34-liter steel...

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