RKI Instruments GD-K77D Operator's Manual
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RKI Instruments GD-K77D Operator's Manual

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Model GD-K77D
Operator's Manual
Part Number: 71-0046RK
Revision: B
Released: 3/1/11
www.rkiinstruments.com

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Summary of Contents for RKI Instruments GD-K77D

  • Page 1 Model GD-K77D Operator’s Manual Part Number: 71-0046RK Revision: B Released: 3/1/11 www.rkiinstruments.com...
  • Page 2 Typical calibration frequencies for most applications are between 3 and 6 months, but can be required more often or less often based on your usage. Model GD-K77D Operator’s Manual...
  • Page 3 Warranty RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free from defects in materials and workmanship, and performance for a period of one year from date of shipment from RKI Instruments, Inc. Any parts found defective within that period will be repaired or replaced, at our option, free of charge.

  • Page 4: Table Of Contents

    Wall Mounting the Model GD-K77D ........
  • Page 5 Parts List............39 Model GD-K77D...

  • Page 6: Overview

    Also keep maintenance records, and use them to plan for future repairs and maintenance of the Model GD-K77D. If the Model GD-K77D is not operated according to the instructions in this manual, RKI Instruments, Inc. cannot assume any responsibility for consequential injury or damage.
  • Page 7 Model GD-K77D properly. CAUTION: This label alerts you to the possibility of injury or damage to the Model GD-K77D when operation and maintenance of the Model GD-K77D are not performed in accordance with the instructions in this manual. When replacing parts for the Model GD-K77D, use only RKI replacement parts.

  • Page 8: Specifications

    WARNING: When using the GD-K77D, you must follow the instructions and warnings in this manual to assure proper and safe operation of the GD-K77D and to minimize the risk of personal injury. Be sure to maintain and periodically calibrate the GD-K77D as described in this manual.

  • Page 9: Description

    Description The Model GD-K77D is designed to measure gas leaks in an industrial setting. Gas leaks are detected by an internal electrochemical sensor, and the gas concentration is displayed by a four-digit LED display. PW/TR LED ALM1 LED 6.05 ALM2 LED...
  • Page 10 Detector unit Cover Wall mounting bracket Figure 2: Removing the Cover and Detector Unit Model GD-K77D 5 • Description Operator’s Manual...

  • Page 11: Case

    The flowmeter checks the sample flow rate of the target gas reaching the sensor inside the Model GD-K77D. The flowmeter is a glass tube on which are marked two red flow lines. A flow ball indicates whether the flow rate is within, or outside, the red flow lines.

  • Page 12: Internal And Back Panel Components

    Internal and Back Panel Components Refer to the diagram below for the location of Model GD-K77D internal and back panel components, which are described below. After each component name is a number, which corresponds to the same number in the diagram.

  • Page 13: Block Diagrams

    CAUTION: When the Model GD-K77D is not used for long periods of time, the lithium battery may lose power. The lithium battery, under normal operating conditions, has a life expectancy of about three (3) years from the date of manufacturing. When the lithium battery is replaced, put the unit into maintenance mode before replacing the battery by pressing the Mode switch for 3 seconds.

  • Page 14: Important Safety Procedures

    Model GD-K77D. Before starting up the Model GD-K77D, make sure an electrical fault has not occurred. Fuse. When replacing the Model GD-K77D’s fuse, turn off the power to the unit. Use only replacement fuses that have the correct current and voltage ratings. Do not use any fuse other than the one specified for the Model GD-K77D.

  • Page 15: Installation

    Dust Filter. When sampling gas from a dusty environment, use the recommend filter to avoid drawing dust into the Model GD-K77D. Place the external dust filter on the end of the hose used to draw in the sample gas. When changing the dust filter, turn off the Model GD-K77D.

  • Page 16: Wall Mounting The Model Gd-K77D

    When installing the wall mounting bracket, make sure to attach it securely to the wall. If not securely attached, the Model GD-K77D may fall causing damage to the unit. Find a suitable location for the Model GD-K77D. Allow enough room around the wall mounting bracket for the Model GD-K77D to be mounted easily.

  • Page 17: Removing The Model Gd-K77D

    Removing the Model GD-K77D Detector Unit When connecting tubing, making electrical connections, or servicing the Model GD-K77D, it is more convenient to remove the Model GD-K77D detector unit from its wall mounting bracket. Loosen this screw Figure 5: Removing the Detector Unit 1.
  • Page 18 The Model GD-K77D can be used to control an external buzzer or alarm light. The Model GD-K77D ‘s external alarm contacts are rated for 0.5 A @ 125 VAC, 1A @ 30 VDC, and 0.5 A @ 60 VDC. Use the alarm contacts on the Model GD-K77D to control only low power devices.
  • Page 19 Model GD-K77D with the appropriate surge protectors. Grounding Attach ground wires to the ground terminals on the Model GD-K77D, labeled chassis (earth) ground bolts in the diagram below, before turning on the power to the Model GD- K77D.
  • Page 20 Chassi s Ground Chassi s Ground Figure 5: Grounding the GD-K77D Model GD-K77D 15 • Installation Operator’s Manual...
  • Page 21 Model GD-K77D by a static electric discharge or by improper grounding. Place the Model GD-K77D detector unit on its side. A vertical placement may cause the unit to fall over, which may damage the unit.
  • Page 22 GD-K77D Terminal Strip N ot ALM1 ALM2 U sed - (DC Ground) + 24 VDC 4 - 20 mA In (FB) Power Source Controller or Recording Device Alarm Device Power Power Source Source Alarm Device Alarm Device Figure 7: Wiring to a Generic Controller, Typical 3-wire Model GD-K77D 17 •...

  • Page 23: Tubing Connections

    PTFE Tubing Figure 8: Inlet/Exhaust Fitting Use Flow Rate The flow rate of the Model GD-K77D is 0.5 L/M (liters per minute) Tubing Material The tubing materials you choose will depend upon the target gas being detected. Some target gases are corrosive while others are absorptive. Choose your tubing materials carefully for both length and material.

  • Page 24: Operation

    Operation Start-up Preparations To avoid the possibility of electrical shock or damage to the Model GD-K77D, follow the precautions listed below before turning on the unit: • Make sure the Model GD-K77D has been properly grounded. • Check all wiring connections to external devices.

  • Page 25: Start Up

    NOTE: The flow rate of the Model GD-K77D is 0.5 LPM. When the flow ball drops below the bottom flow line, the Model GD-K77D cannot accurately detect the target gas. Increase the flow rate. CAUTION: Allow the unit to warm-up for 2 hours before setting the zero reading.
  • Page 26 The LED display will show the concentration of the target gas. The example below illustrates an alarm 1 condition with a gas concentration of 0.5 ppm. LED indication Display indication ALM1 PW/TR ALM2 SKIP Model GD-K77D 21 • Operation Operator’s Manual...
  • Page 27 Trouble Conditions The following table shows the possible trouble conditions that may occur: Table 3: Trouble Conditions Display Condition E-00 System Fault E-01 Sensor Disconnected E-04 Zero Suppression Trouble E-05 Low Flow Alarm Model GD-K77D Operator’s Manual Operation • 22...

  • Page 28: Maintenance Mode

    Figure 10: 4-20 mA output vs. Gas Concentration Maintenance Mode There are two maintenance modes for the Model GD-K77D: Maintenance Mode 1 and Maintenance Mode 2. Under Maintenance Mode 1, you can perform a zero adjustment and confirm the alarm points. Under Maintenance Mode 2, you can confirm bias voltage (optional), perform a zero adjustment, perform a span adjustment, and determine a sensor’s start-up time.
  • Page 29 The relay contact will be reset and the 4-20 mA output will lock on 2.5 mA. Zero Adjustment A zero adjustment resets the Model GD-K77D’s gas detecting system to zero so it can accurately sample the target gas. This test should be done periodically, such as once a month.
  • Page 30 If you suspect the target gas is in the area being monitored, supply zero air to the Model GD-K77D before setting the zero adjustment. 1. With the front control cover of the Model GD-K77D flipped open, press and hold the Mode switch for three seconds to start Maintenance Mode 1. The display will show 1- 1 and the Skip light will flash.
  • Page 31 CAUTION: The gas alarms will only work in Detection Mode. If the Model GD-K77D is left in Mode Maintenance Mode for ten hours or more, it will switch to Detection automatically. Alarm Point Confirmation When checking the alarm point, follow these steps: 1.
  • Page 32 PW/TR ALM1 ALM2 SKIP CAUTION: The gas alarms will only work in Detection Mode. If the Model GD-K77D is left in Maintenance Mode for ten hours or more, it will switch to Detection Mode automatically. Maintenance Mode Summary Mode No.

  • Page 33: Alarm Test Mode

    Model GD-K77D. 1. With the front control cover of the Model GD-K77D flipped open, press and hold the TEST/SET switch for three seconds to start alarm test mode. The Skip light and display indication will flash.

  • Page 34: Alarms

    Trouble Alarm. A trouble alarm is activated when a fault is detected in the Model GD- K77D. Except for system fault (E-00), a trouble alarm is self-resetting. When the Model GD-K77D returns to normal after a trouble alarm has occurred, the unit starts its warm-up cycle, which runs for 25 seconds before Detection Mode commences.

  • Page 35: Responding To Alarms

    Set the correct flow rate with the flow adjust valve. If you cannot set the correct flow rate, check the sample lines for obstructions or kinks. Calibrate the Model GD-K77D. If the fail condition continues, contact RKI Instruments, Inc. for further instruction.

  • Page 36: Maintenance

    Flowmeter. Check the flowmeter to make sure the flow ball is between the two red flow lines. The flow rate of the Model GD-K77D is 500cc/min. If the flow ball is not between the red flow lines, adjust the air flow. When the flow ball is above the top flow line, press the FLOW ADJ switch down to reduce the flow rate.

  • Page 37: Calibration

    RKI Instruments Inc. recommends you calibrate the Model GD-K77D every six months. NOTE: If the GD-K77D is installed in a clean room environment, the calibration frequency may be extended to yearly. Adjusting the Zero Setting 1.
  • Page 38 7. Press the TEST/SET switch to put the unit in Zero Adjustment Mode. 8. Press the TEST/SET switch to zero the unit. The GD-K77D is finished adjusting the zero after the display stops flashing. 9. Press the MODE switch to return to Maintenance Mode 2.
  • Page 39 Detection Mode. Setting a Sensor’s Start-up Time This procedure performs internal setup in the GD-K77D specific to the new sensor so that the unit will be able to determine when the sensor’s output becomes too low to operate properly.

  • Page 40: Storage

    Detection Mode. Storage If you need to store the Model GD-K77D temporarily or for long periods of time, make sure that the unit is oriented upright with the display facing forward. This orientation will help minimize the normal aging of the sensor and keep the sensor membrane from drying out.

  • Page 41: Replacing Components

    This section describes how to change the sensor, pump, and fuse. Replacing the Sensor 1. Turn off the GD-K77D power switch. Also verify that the power to the unit is off. 2. Loosen the thumbscrew on the front of the cover and pull the cover away.

  • Page 42: Troubleshooting

    Prevention A trouble alarm may result from disconnected wiring or short circuits between the Model GD-K77D and devices connected to it. To reduce the reduce the possibility of a trouble alarm, do the following: • Check the wiring on the Model GD-K77D as well as the wiring on all peripheral equipment.

  • Page 43: Pw/Tr Lamp Off

    Check the flowmeter to make sure the flow ball is between the two red flow lines. The flow rate of the Model GD-K77D is 500 L/min. If the flow ball is not between the red flow lines, adjust the flow rate. When the flow ball is above the top flow line, press the FLOW ADJ switch down to reduce the flow rate.

  • Page 44: Disconnected Fuse

    Check that the Model GD-K77D is mounted firmly or that the fixing screw is fastened securely. • The tubing on the gas-in or gas-out side of the Model GD-K77D may be clogged or broken. Check and repair the pipes as required. Disconnected Fuse •...

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Gd-k77d-nt

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