RKI Instruments 35-3000RKA-10 User Manual
35-3000RKA-10
PPM Hexane Sample Draw
Detector Operator’s Manual
Part Number: 71-0151RK
Revision P1
Released: 10/11/07
RKI Instruments, Inc.
www.rkiinstruments.com
Product Warranty
RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free from defects in
materials, workmanship, and performance for a period of one year* from the date of
shipment from RKI Instruments, Inc. Any parts found defective within that period will be
repaired or replaced, at our option, free of charge. Parts must be returned to RKI
Instruments, Inc. for repair or replacement. This warranty does not apply to those items
which by their nature are subject to deterioration or consumption in normal service, and
which must be cleaned, repaired or replaced on a routine basis. Examples of such items
are:
a) Pump diaphragms and valves c) Batteries
b) Fuses d) Filter elements
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 LIMITED TO, THE WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO
EVENT SHALL RKI INSTRUMENTS, INC. BE LIABLE FOR INDIRECT,
INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGE OF ANY KIND
CONNECTED WITH THE USE OF ITS PRODUCTS OR FAILURE OF ITS
PRODUCTS TO FUNCTION OR OPERATE PROPERLY.
This warranty covers instruments and parts sold to users only by authorized distributors,
dealers and representatives as appointed by RKI Instruments, Inc.
We do not assume indemnification for any accident or damage caused by the operation of
this gas monitor and our warranty is limited to the replacement of parts or our complete
goods. Warranty covers parts and labor performed at RKI Instruments, Inc. only, and does
not cover field labor or shipment of parts back to RKI.
2 • 35-3000RK-10 PPM Hexane Sample Draw Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Detection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting the Sample Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting the Sample Lines to the Sample Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wiring the Sample Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sample Draw Detector Burn-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing Components of the Sample Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjusting the Low Flow Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Detector Load Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Calibration Kit Humidifier Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembling the Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
35-3000RK-10 PPM Hexane Sample Draw Dete ctor • 3
Overview
This manual describes the 35-3000RKA-10 ppm hexane sample draw detector. This
manual also describes how to install, star t up, configure, maintain, and calibrate the
sample draw detector when it is used with a gas monitoring controller. A parts list at the
end of this manual lists replacement parts and accessories for the sample draw detector.
Specifications
Table 1 lists specif ications for the sample draw detector.
Description Specification
Input Power 18 - 30 VDC
Target Gas Combustible Gas, Cali brated to Hexane
Detection Range 0-500 ppm Hexane
Construction Fiberglass/polyester NEMA 4X Housing
Table 1:Specifications
Dimensions 8.5 in. H x 6.5 in W x 4.25 in. D
Weight 4.5 pounds
Sampling Method Sample Draw
Sample Flow 1.5 SCFH nominal
Signal Output 4 to 20 mA, 500 ohm impedance max.
Response Time 90% in 30 seconds
Accuracy
± 5% of detection range
4 • 35-3000RK-10 PPM Hexane Sample Draw Detector
Description
This section describes the components of the sample draw detector. It is a 4 to 20 mA type
detector head. The sample draw detector consists of the housing, flow system, and
detection system.
Flow Adjust Pot
Pum p/Flo w Switch
Terminal Strip
Main Circuit Board
Fail LED
Pilot LED
Flowmeter
Bypass valve
Hydrophobic Filter
(Behind Ma in
Cir cuit B oard )
Load Voltage Po t
Amplifier Plate
Factory Use Jump er Strip
- Test Point, Black
Ga s Sele c tion Ju mp er,
In Hexane Position
+ Test Point, Red
Factory Set Pots
Factory Us e Jumper Str ip
Amplifier
1
2
3
4
Gas Select
1-2 Hex
3-4 H2
DETECTOR
Moun t i ng Foot, 4X
ZER O
SPAN
SWBR
PWR/ SIG
Flow Alarm Setpoint
Adju stment Screw
Detector/Amplifier
Terminal Strip
Interconnect
Terminal Strip
Exhaust
Inlet
Zero Pot
Span Pot
Flow Block
Chamber
Not Used
ppm Hexane
Detector
Controller
Terminal Strip
3/4" Conduit Hu b, 2X
Detector
Terminal Strip
Figure 1: Component Location
Housing
The sample draw detector’s fiberglass housing is weather- and corrosion-resistant. It is
suitable for installation where general purpose equipment is in use.
The housing door is hinged on the left side and is secured by two latches on the right side.
The flowmeter and status LEDs are visible through a window in the housing door.
Four mounting feet are attached to the back of the housing (one at each corner). Use the
mounting feet to install the housing to a vertical surface. Use the two conduit hubs on the
bottom of the housing to make wiring connections.
An aluminum subpanel is mounted to th e interior of the housing. The sample draw
detector’s internal components are mounted to the subpanel.
35-3000RK-10 PPM Hexane Sample Draw Dete ctor • 5
Flow System
The sample draw detector’s flow system consists of the inlet fitting, exhaust fitting, pump,
flowmeter, bypass valve, flow block, status LEDs, and pressure switch (see Figure 1).
Figure 2 below illus trates how the gas sample moves through the flow system.
Bypass
Valve
Inlet
Hydrophobic
Filter
Pump
Detector
Figure 2: Flow Diagram
Flowmeter
Presur e Swit ch
Exhaust
Inlet Fitting
The inlet fitting on the right side of the housing allows the gas sample to enter the sampledraw detector. The inlet fitting accepts 1/4 in. rigid tubing. See “Connecting the Sample
Lines to the Sample Draw Detector” on pag e 11 to connect tubing to the inlet fitting.
Exhaust Fitting
The exhaust fitting on the right side of the housing allows the gas sample to exit the
sample draw detector. The exhaust fitting accepts 1/4 in. rigid tubing. See the
“Connecting the Sample Lines to the Sample Draw Detector” on page 11 to connect tubing
to the exhaust fitting.
Hydrophobic Filter
The hydrophobic filter is behind the main circuit board near the bottom edge of the board.
The filter prevents particulates and water in the incoming gas sample from damaging the
flow and detection systems. Replace the filter when it appears dirty, discolored, or
clogged.
Pump
The pump is behind the main circuit board near the top of the sample-draw detector.
The pump pulls the gas sample into the sample-draw detector. The pump operates on
24 VAC, which is generated f rom the 24 VDC supplied to the sample draw detector.
Flowmeter
The flowmeter is attached to the main circuit board near the top left corner (see Figure 1.)
You can see it through the window in the door. A ball in the flowmeter column indicates
the flow rate of the sample draw detector. The flowmeter measures the flow in the range
0.2 to 2.0 SCFH (Standard Cubic Feet per Hour). The optimum flow rate is 1.5 SCFH.
6 • 35-3000RK-10 PPM Hexane Sample Draw Detector
Bypass valve
The bypass valve is to the left of the flowmeter. The bypass valve adjusts the flow rate to
the detector. U se a flat-bla de screwdriver to adjust the bypass valve.
NOTE: The bypass valve allows fine adjustments of the f low rate to the detector. To
adjust the total flow and for a wider range of adjustment, use the flow adjust pot
(see Figure 1).
Flow Block
The flow block is an aluminum block with a chamber for the detector and passages that
route the sample to and from the detector. It is located in the lower right corner of the
sample draw detector. The flow block has an unused chamber that is used for an oxygen
detector in other versions of the 35-3000RK.
Status LEDs
T wo status L EDs are above the flowmeter. They are also visible through the window in the
housing door.
Pilot LED
The green Pilot LED is on when the sample-draw detector is receiving power from the
Pioneer.
Fail LED
The red Fail LED is on when the sample flow rate is below the low flow level.
Pressure switch
The pressure switch is mounted to the opposite side of the main circuit board. The
pressure switch monitors the flow rate of the incoming gas sample.
If the flow rate falls below the preset low flow level, the pressure switch causes the fail
relay to interrupt the signal in the 4-20 mA line. This causes a downscale reading at the
monitor. The low flow level is factory set at 0.6 SCFH (±0.2 SC FH). See “Adjusting the
Low Flow Setting” on page 20 to adjust this setting if necessary.
Detection System
The detection system consists of the ppm hexane detector, the amplifier, and the main
circuit board.
PPM Hexane Detector
The ppm hexane detector is a MOS type (metal oxide semiconductor) detector packaged
in a 5 pin plug-in detector housing with a sintered metal flame arrestor on one end
allowing ambient air to diffuse into the detector. The flame arre stor also contains any
sparks which may occur within the detector. The 5 pins allow you to connect the detector
to the detector cable which has a mating 5 pin connector. The three color-coded leads of
the detector cable allow you to connect the detector to the amplifier. The output of the
detector is non-linear and is linearized by th e am plifier (see below).
The detector is installed in an aluminum flow block. The flow block is mounted to the
aluminum subpanel near the bottom right corner of the sample draw detector.
NOTE: The flow block includes a chamber for an oxygen sensor. This version of the
sample draw detector does not include the oxygen sensor.
35-3000RK-10 PPM Hexane Sample Draw Dete ctor • 7
Amplifier
The amplifier is mounted to the left of the detector. It is installed on a small plate with
adhesive foam and the plate is mounted to two standoffs. The amplifier converts the nonlinear electrical output from the detector to a linear 4 to 20 mA signal that corresponds to
the detection range and transmits the signal to a gas monitoring controller. The a mplifier
consists of the span pot, zero pot, load voltage pot, gas select jumper strip, controller
terminal strip, detector terminal strip and test points.
Zero Pot
The zero pot is located in the upper right corner of the amplifier (see Figure 1). Use a small
flat blade screwdriver to turn the zero pot’s adjustment screw and adjust the amplifier’s
zero (fresh air) output during the start-up and calibration procedures.
Span Pot
The span pot is located below the zero pot (see Figure 1). Use a small flat blade
screwdriver to turn the span pot’s adjustment screw and adjust the amplifier’s gas
response output du ring the calibration procedure.
Load voltage pot
The load voltage pot is located to the left of the zero and span pots (see Figure 1). The load
voltage pot is not needed for normal scheduled maintenance, so it is a right angle pot that
is not accessible unless the amplifier is lifted out of the sample draw detector enough to
access the adjustment screw. Use a small flat blade screwdriver to turn the load voltage
pot’s adjustment screw and adjust the amplifier’s detector load voltage when the detector
or amplifier is replaced.
CAUTION: The amplifier includes additional pots. They are factory-set. Do not adjust the m.
Gas Select Jumper Strip
The gas select jumper strip is a three position pin style terminal strip located in the upper
left corner of the amplifier. A label next to the jumper strip indicates which pins must be
shorted to select hexane or hydrogen. A jumper block is installed at the factory over pins 1
& 2 to select hexane as the gas type. The gas type defines the linearizing curve used by the
amplifier to linearize the detector output.
Controller and Detector Terminal Strips
The controller terminal strip and detector terminal strip are three position terminal strips.
The controller terminal strip is located on the right side of the amplifier and the detector
terminal strip is to the right of it. Both terminal strips are factory wired to the sensor and
main circuit board.
Test points
The test points are located on the left side of the amplifier. The black - test point is in the
upper left corner and the red + test point is located below it on the other side of the gas
select jumper strip. A 100 mV - 500 mV output is available at these test points for use
during calibration.
8 • 35-3000RK-10 PPM Hexane Sample Draw Detector
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