RKI Instruments 35-3001-01-02 User Manual

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35-3001-01-02

Combustible Gas Sample-Draw Detector

Operator’s Manual

Part Number: 71-0322RK Revision: P2 Released: 9/17/14

www.rkiinstruments.com

WARNING

Read and understand this instruction manual before operating detector . Improper use of the dete ctor could result in bodily harm or death.

Periodic calibration and maintenance of the detector is essential for proper operation and correct readings. Please calibrate and maintain this detector regularly! Frequency of calibration depends upon the type of use you have and the sensor types. T ypical calibration frequencies for most applications a re between 6 and 12 months, but can be required more often or less often based on your usage.

35-3001-01-02 Combustible Gas Sample-Draw Detector

Product Warranty

RKI Instruments, Inc. warrants gas alarm equipment s old by us t o be free from def ects in material s, 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. This warrant y does not apply to those items which by their nature are subject to deterioration or consumption in normal service, and which must b e cleaned, repaired, o r replaced on a routine basis. Examples of such items are:

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or repair procedures not in accordance with the operator’s manual. This warranty indicates the full extent 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 N OT LIMITED T O, 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.

a) Absorbent cartridges d) Batteries b) Pump diaphragms and valves e) Filter elements c) Fuses

This warranty covers instruments and parts sold to users 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.

35-3 001-01-02 Combustible Gas Sample- Draw Detector

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

External Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Mounting the Combustible Gas Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Removing the Inlet Fitting Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Connecting the Sample Lines to the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wiring the Combustible Gas Sample-Draw Detector to a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Introducing Incoming Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replacing Components of the Combustible Gas Sample-Draw D etector. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

35-3001-01-02 Combustible Gas Sample-Draw Detector

Overview

This operator’s manual describes the 35-3001-01-02 combustible gas sample-draw detector. This manual also describes how to install, start up, maintain, and calibrate the sample-draw detector when using it 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 specifications for the combustible gas sample-draw detector. See the controller Operator’s Manual for information specific to the controller.

Target Gas and Detection Range General hydrocarbons (calib rated to propane): 0 - 100% LEL Input Power 24 VDC Nominal (18.5 VDC - 30 VDC) Construction (housing) Fiberglass/polyester (NEMA 4X) Dimensions 8.5 in. H x 6.5 in. W x 4.25 in. D

Table 1: Specifications

W eight 4.5 lbs. Sampling Method Sample-draw Sample Flow 3.0 SCFH typical, with no inlet or exhaust line Flow to Sensor 1.0 SCFH (nominal) Maximum Recommended Inlet/

Exhaust Line Length for 1/4” O.D. x 1/8” I.D. Tubing

Maximum Recommended Inlet/ Exhaust Line Length for 1/4” O.D. x 0.170” I.D. Tubing

Response Time 90% in 30 seconds Accuracy ± 5% of reading or ± 2% of full scale (whichever is greater)

W ARNIN G: When using the 35-3001-01-0 2, you mus t follow the ins truction s and warnin gs in

this manual to assure proper and safe operation of the 35-3001-01-02 and to minimize the risk of personal injury. Be sure to maintain and periodically calibrate the 35-3001-01-02 as described in this manual.

Inlet

100 feet 0 feet

50 feet 50 feet

Inlet

100 feet 100 feet

Exhaust

35-3001-01-02 Co m b u s t i b l e G a s Sample-Draw De t e c t o r • 1

Description

Pump Connector

Sensor Flow

Control Valve

Fail LE D

Pilot LED

Pump Reset

Switch

Flowmeter

This section describes the components of the combustible gas sample-draw detector.

Oxygen

Flowmeter Circuit

Board Connector

Mounting

Foot, 4X

Y G

Sensor Terminal Strip

Pump

IR HC Sensor (inside block)

IR HC Flo w Bl o ck

IR HC Sensor PCB

Pressure Switch

Adjustment Screw

(behind PCB)

Hydrophobic

This End To

Inlet Fitting

Particle Filter

Filter

Inlet

Fitting

Exhaust

Fitting

INLET

EXHAUST

Detector/Amp Terminal Strip

AMP 2SOXY

AMP

AMP 1

AMP 2

OXY

LEL/ IR

R BG

LEL/ IR

(Factory Wired)

Interconnect Terminal Strip

3/4" Conduit Hub

Figure 1: Combusti bl e Gas Sa mp l e-Draw Detector Component Location

External Components

This section describes the sample-draw detector’s external components.

Housing

The sample-draw detector’s fiberglass housing is weather- and corrosion-resistant. It is suitable fo r

2 • 35-3001-01-02 Combusti ble Gas Sample-Draw Det ector

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.

Sample Fittings

The sample fittings are located on the left side of the bottom of the housing. The inlet fitting is near the front of the housing and the exhaust fitting is near the back of the housing. The inlet fitting has a short factory installed tubing stub for use with the particle filter. The sample fittings accept 1/4 in. rigid tubing. See the Installation section on page 6 to connect tubing to the sample fittings.

Inlet Fitting Tubing Stub

A short tubing stub comes factory installed in the inlet fittin g. It is used for connecting the particle filter. If the particle filter is not used, or if you install the particle filter in a different location, the tubing stub needs to be removed and replaced with tubing.

Conduit Hub

One 3/4” conduit hub is located on the right sid e of the bottom of the hous ing. It is used fo r routing wiring into the housing by using conduit or an appropriate cable bushing.

Internal Components

This section describes the sample-draw detector’s internal components (see Figure 1). Figure 2 illustrates how the gas sample moves through the flow system.

Exhaust

Inlet

ParticleFilter

Pressure Switch

Flowmeter PCB

Restrictor

Flowmeter

IR HC

Sensor

Flow

Control

Valve

Pump

HydrophobicFilter

Figure 2: Combustible Gas Sample-Draw Detector Flow Diagram

Main Circuit Board

The main circuit board includes the detect or/amp terminal strip, intercon nect terminal st rip, oxygen sensor terminal strip, pump connector, and flowmet er circuit board connector (see Figure 1).

35-3001-01-02 Co m b u s t i b l e G a s Sample-Draw De t e c t o r • 3

Detector/Amp Terminal Strip

The detector/amp terminal strip is the upper twelve-point terminal strip in the bot tom right corner of the main circuit board. Use the detector/amp terminal strip to connect the IR HC sensor to the main circuit board.

NOTE: The IR HC sensor is factory-wired to the main circuit board. See the “Installation”

section on page 6 for all wiring procedures related to the sample-draw detector.

Interconnect Terminal Strip

The interconnect terminal strip is the lower twelve-point terminal strip in the bottom right corner of the main circuit board. Use the interconnect termin al stri p to con n ect the sam ple-draw detector to a controller.

Oxygen Sensor Terminal Strip

The oxygen sensor terminal strip is a two-point terminal strip in the upper right corner of the main circuit board. This terminal strip is not used in this version of the sample-draw detector.

Pump Connector

The pump connector is the two-point connector below the oxygen terminal strip in the upper right corner of the main circuit board. Use the pump co nnector to connect the pump to the main circuit board.

NOTE: The pump is factory-wired to the main circuit board. See “Installation” on page 6 for all

wiring procedures related to the sample-draw detector.

Flowmeter Circuit Board Connector

The flowmeter circuit board connector is a six-position connector in the upper left corner of the main circuit board. Use the flowmeter circuit board connector to connect the flowmeter circuit board to the main circuit board.

NOTE: The flowmeter circuit board is factory wired to the main circuit board. See “Installation”

on page 6 for all wiring procedures related to the sample-draw detector.

Flowmeter Circuit Board

The flowmeter circuit board is mounted to the left side of the main circuit board using standoffs. It includes the flowmeter, sensor flow control valve, status LEDs, pressure switch, and pump reset switch.

Flowmeter

The flowmeter is mounted to the right side of the flowmeter circuit board. You can see it through the window in the door. A ball in the flowmeter column indicates the flow rate to the sensor. The flowmeter measures the flow in the range 0.2 to 2.0 SCFH (Standard Cubic Feet per Hour). The optimum flow rate is 1.0 SCFH.

Sensor Flow Control Valve

The sensor flow control valve is mounted to the flowmeter circuit board above the flowmeter. The sensor flow control valve adjusts the flow rate to the detector. Turn the valve’s knob counterclockwise to increase the flow and clockwise to decrease the flow.

Status LEDs

T wo status LEDs are abov e the flowmeter. They are also visible through the windo w in t he hou sing

4 • 35-3001-01-02 Combusti ble Gas Sample-Draw Det ector

door. The green Pilot LED is on when the sample-draw detector is receiving power from the controller. 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 back of the flowmeter 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 LED to turn on and interrupts the signal from the detector. The interrupted detector signal causes a fail condition at the controller. The low flow level is factory-set at 0.6 SCFH (±0.1 SCFH). See “Adjusting the Low Flow Setting” on page 15 to adjust this setting.

Pump Reset Switch

The pump reset switch is located to the left of the status LEDs. When a low flow condition occurs, the pump will be shut off. To reset the low flow condition and start the pump again, press and hold the pump reset switch for about 2 seconds, then release.

Hydrophobic Filter

The hydrophobic filter is located toward the bottom left of the main circuit 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 mounted to the right side of the main circuit board. The pump pulls the gas sample into the sample-draw detector. The pump operates on 24 VAC, which is generated from the 24 VDC supplied by the controller.

IR HC Sensor/IR HC Sensor PCB

The IR HC sensor is an infrared type plug-in detector. Infrared combustible detectors are generally used instead of the catalytic combustible detectors in applications where there may be catalyst poisons such as silicone present or where oxygen is not present in the monitoring environment.

The IR HC sensor is installed in the IR H C flo w blo ck and the IR HC fl ow bl o ck i s mount ed t o the middle of the main circuit board. A small circuit board, the IR HC sensor PCB, wi th a 4-wire cable mates to the IR HC sensor and retains it in the flow block. The cable is wired to the main PCB. The IR HC sensor PCB allows you to replace the sensor without disconnecting the wiring.

35-3001-01-02 Co m b u s t i b l e G a s Sample-Draw De t e c t o r • 5

Installation

This section describes procedures to mount the sample-draw detector in the monitoring environment and wire the sample-draw detector to a controller.

Mounting the Combustible Gas Sample-Draw Detector

1. Select the mounting site. Consider the following when you select the mounting site:

• Is there enough room to open the housing door and make wi ring and tubi ng connect io ns at the bottom of the housing?

• Make sure there is sufficient room to perform start-up, maintenance, and calibration procedures.

• Are the flowmeter and status LEDs visible?

6.50

1.13

Ø.30x.50(4X)MOUNTING

.78

.40

8.50

Pil o t Fail

Sa mple Drawing

Gas Dete ctor

ww w.rkiinstruments.com

4.00

35-3001

8.88

.80

.85

4.50

NOTE: Housing is 4.3 inchesdeep

Figure 3: Outline and Mounting Dimensions

6 • 35-3001-01-02 Combusti ble Gas Sample-Draw Det ector

2. Close and latch the housing door.

NOTE: The sample-draw detector is shipped with the mounting feet “tucked under” the housing

to protect the mounting feet during shipment.

3. Slightly loosen the screw that secures the mounting foot to the housing, then rotate the mounting foot 180 degrees (see Figure 3).

4. Tighten the screw that secures the mounting foot to the housing.

5. Repeat steps 3 and 4 for the remaining three mounting feet.

6. Position the sample-draw housing on a verti cal surface at eye level (4 1/2 to 5 feet from the floor).

7. Insert 1/4 inch screws through the slots in the mounting feet to secure the housing to the mounting surface.

Removing the Inlet Fitting Tubing Stub, if Necessary

O-ring

Tube Nut

1/4" Tube

Inside of Case

Outside of Case

Fitting Body

Back Ferrule

Front Ferrule

1/4 " Tube

Figure 4: Inlet Fitting with Tubing Stub

CAUTION: Do not pull the tubing stub downward to remove it.

1. Unscrew the outside inlet fitting tube nut from the fitting body. The tubing stub should come out with the tube nut. Be careful not to lose the O-ring that may come out with the tubing stub.

2. Push the tubing stub up and out of the front ferrul e being careful not to lose the ferrule set.

3. Push the new tubing up through the inlet fitting tube nut and replace the ferrule set and the O-

35-3001-01-02 Co m b u s t i b l e G a s Sample-Draw De t e c t o r • 7

ring, if it came out, in the orientation shown in Figure 4.

4. Screw the inlet fitting tube nut back onto the fitting body. See the next section for instructions to install a new piece of tubing into the fitting.

Connecting the Sample Lines to the Sample-Draw Detector

See Figure 4 for the fitting layout.

Installing the Inlet Line with Particle Filter

1. Connect the particle filter to the tubing stub on the inlet by pushing the flexible tubing on the filter onto the stub. Be sure the arrow on the particle filter is pointing toward the inlet fitting.

2. Connect a length of sample tubing to the other side of the particle filter and route it to the sampling area. 1/4” O.D. rigid polypropylene, Teflon, or flexible polyurethane tubing may be used. RKI Instruments , Inc. recomm ends using either 1/4” O.D. x 1/8” I.D. or 1/4” O.D. x

0.170” I.D. tubing based on your length requirements. See “Specifications” on page 1 for maximum tubing lengths based on tubing size.

CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate

insert if necessary to provide support to the tubing and ensure a good seal when connecting to the flexible stub on the filter.

CAUTION: Avoid lo ops or slumps in the incoming sample lin e. To reduce r esponse time, keep the

incoming sample line as short as possible.

Installing the Inlet Line without Particle Filter

1. Remove the tubing stub as described in “Removing the Inlet Fitting Tubing Stub, if Necessary” on page 7.

2. Loosen the nut on the inlet fitting until 3 threads are visible.

3. Push 1/4” O.D. rigid polypropylene or rigid Teflon sample tubing into the fitting until it stops. Flexible polyurethane tubing may be used with an appropriate insert. RKI Instruments, Inc. recommends using either 1/4” O.D. x 1/8” I.D . or 1/4” O.D. x 0. 170” I.D. t ubing based o n your length requirements. See “Specifications” on page 1 for maximum tubing lengths based on tubing size.

CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate

insert to seal the connection between the tubing and the inlet fitting.

4. Hand tighten the nut on the inlet fitting so the ferrules clamp on the tubing. If the tube nut is removed, see Figure 4 for the arrangement of the fitting components.

5. Route tubing from the inlet fitting to the sample area. See “Specifications” on page 1 for maximum tubing lengths based on tubing size.

CAUTION: Avoid lo ops or slumps in the incoming sample lin e. To reduce r esponse time, keep the

incoming sample line as short as possible.

8 • 35-3001-01-02 Combusti ble Gas Sample-Draw Det ector

Installing the Exhaust Line

1. Loosen the nut on the exhaust fitting until 3 threads are visible.

2. Push 1/4” O.D. rigid polypropylene or rigid Teflon sample tubing into the fitting until it stops. Flexible polyurethane tubing may be used with an appropriate insert. RKI Instruments, Inc. recommends using either 1/4” O.D. x 1/8” I.D . or 1/4” O.D. x 0. 170” I.D. t ubing based o n your length requirements. See “Specifications” on page 1 for maximum tubing lengths based on tubing size.

CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate

insert to seal the connection between the tubing and the inlet fitting.

3. Hand tighten the nut on the exhaust fitting so the ferrules clamp on the tubing. If the tube nut is removed, see Figure 4 for the arrangement of the fitting components.

4. Route the opposite end of the tu bing t o an op en area where the sample can safely disp erse or to an exhaust duct. See “Specifications ” on page 1 for maximum tubing lengths based on tubing size.

Wiring the Combustible Gas Sample-Draw Detector to a Controller

WARNING : Always verify that the controller is off and that power to the controller is off

before you make wiring connections.

1. Turn off the controller.

2. Turn off power to the controller.

3. Unlatch and open the housing door of the sample-draw detector.

4. Guide a six-conductor, shielded cable or six wires in conduit through the conduit hub at the bottom of the sample-d raw housing. A minimum of 18 AWG wire is recommen ded.

5. Connect the cable to the sample-draw detector’s interconnect terminal strip as shown in Figure

6. Close and latch the housing door of the sample-draw detector.

CAUTION: If using shielded cable, leave the cable shield’s drain wire insulated and

disconnected at the sample-draw detector. You will connect the opposite end of the drain wire at the controller.

7. Route the cable or wires in conduit leading from the sample-draw detector through one of the conduit hubs at the controller.

35-3001-01-02 Co m b u s t i b l e G a s Sample-Draw De t e c t o r • 9

8. Connect the wires to the applicable detector/transmitter terminal strip at th e contr oller as

shown in Figure 5. Refer to the controller operator’s manual and the controller detector head specification sheet for the 35-3001-01-02 for detector/terminal strip connections specific to the controller.

Not Used on

Th is Versio n

Black Gree Whit Red

C ontrol l er Detector/

Transmitter Te rminal

Strip Terminals

Controller D etector/

Transm it t er Terminal

Strip, LEL Detector

Term in als

9. If shielded cable is used, connect the cable’s drain wire to an available chassis (earth) ground at the controller. RKI controllers typically have a ground stud that can be used to ground the cable’s drain wire.

AMP 1

AMP 2 LEL/IR

OXY

LEL/IR

AMP 2

PATS101PATS101PATS201PATS201

+24VDC

- (DC Ground)

Red

White

Green

Black

Figure 5: Wiring the Sample-Draw Detector to a Controller

To I R HC

Sensor

10 • 35-3001-01-02 Combustible Gas Sample-Draw Detecto r

Start Up

This section describes procedures to start up the sample-draw detector and place the sample-draw detector into normal operation.

Introducing Incoming Power

1. Complete the installation procedures described earlier in this m anual.

2. Verify that the wiring is correct and secure. Refer to the controller operator’s manual for connections at the controller.

3. Turn on or plug in the power to the controller, then turn on the controll er.

4. Verify that the sample-draw detector’s Pilot LED is on.

5. Verify that the controller is on and operating properly. Refer to the controller operator’s manual.

6. Verify that the flowmeter indicates a flow rate of approximately 1.0 SCFH. If necessary, use the sensor flow control valve to adjust the flow rate. Turn the valve’s knob counterclockwise to increase the flow and clockwise to decrease the flow.

NOTE: The following step tests for leaks in the sample line. This test will cause a low flow

condition at the sample-draw detector and a fail condition at the controller. Be sure to put the controller into its calibration program or disable external alarms before performing this test.

7. Verify that the incoming sample line is not leaking. To test the sample line, press and hold the reset switch and plug the open end of the sample line with your thumb. If the flowmeter ball drops to the bottom of the flowmeter, the incoming sample line is not leaking.

8. Remove your thumb from the sample line, release the reset switch, and verify the flowmeter returns to a normal flow rate.

9. Enable alarms or place the controller in normal operation.

CAUTION: Allow the sample-draw detector to warm up for 5 minutes before you continue with

the next section, “Setting the Zero Reading.”

Setting the Zero Reading

CAUTION: If you suspect the presence of combustible gas in the monitoring environment, use

the calibration kit and the zero air calibration cylinder to introduce “fresh air” to the sensor and verify an accurate zero setting. See “Calibration” on page 16 for instructions on using a zero air calibration cylinder for setting the zero reading.

1. Verify that the sample-draw detector is sampling a fresh air environmen t (env iron ment known to be free of combustible gas).

2. Verify a reading of 0 %LEL on the controller display screen for the applicable channel. If the display reading is 0 %LEL, start up is complete. The sample-draw detector is in normal

operation. If the display reading is not 0 %LEL, continue with step 3.

3. Perform a zero operation at the controller. See “Setting the Zero Reading” on page 16 and the controller operator’ s manual for inst ru cti ons to perform a zero operation .

35-3001-01-02 Com b us ti b le Ga s Sample-Draw Det e ct or • 1 1

Maintenance

This section describes maintenance procedures. It includes preventive maintenance procedures. This section also includes procedures to troubleshoot the sample-draw detector, replace components of the sample-draw detector, and adjust the low flow setting.

Preventive Maintenance

This section describes a preventive maintenance schedule to ensure the optimum performance of the sample-draw detector. It includes daily, monthly, and biannual procedures.

Daily Visual Checks

1. Verify that the Pilot LED is on.

2. Verify that the flowmeter indicates a flow rate of approximately 1.0 SCFH. If necessary use the

3. Verify a display reading of 0 %LEL at the controller. Investigate significant changes in the

Monthly Response Test

This procedure describes a test to verify that the sample-draw detector responds properly to the target gas.

sensor flow control valve to adjust the flow rate to 1.0 SCFH. Turn the valve’s knob counterclockwise to increase the flow and clockwise to decrease the flow.

display reading.

NOTE: To reduce the response time of this test, use a short incoming sample line. If the sample-

draw detector’s sample line is long, connect a shorter line for this test. Make sure you reconnect the sample line after you complete this procedure.

NOTE: Performing a response test on the sample-draw detector may cause alarms. Be sure to put

the controller into its calibration program or disable external alarms before performing this test.

Preparing for the response test

NOTE: This procedure describes the RKI calibration kit that includes a demand flow re gulator.

1. Verify that the display reading at the controller is 0 %LEL. If the display reading is not 0 %LEL, set the zero reading as described in “Calibration” on

page 16, then continue this procedure.

Performing the response test

1. Screw the demand flow regulator into the calibration cylinder.

2. Connect the calibration tubing from the demand flow regulator to the inlet fi tting. Gas will begin to flow.

3. After approximately one minute, verify that the reading at the controller stabilizes within ± 20% of the concentration of the test sample. If the reading is not within ± 20% of the test sample, calibrate the sample-draw detector as described in “Calibration” on page 16.

4. Remove the calibration tubing from the inlet fitting, then reconnect the sample tubing to th e inlet fitting.

12 • 35-3001-01-02 Combustible Gas Sample-Draw Detecto r

5. Store the calibration kit in a safe place.

Biannual Calibration

Calibrate the sample-draw detector as described in “Calibration” on page 16.

Troubleshooting

The troubleshooting guide describes symptoms, probable causes, and recommended action for problems you may encounter with the sample-draw detector.

NOTE: This troubleshooting guide describes sample-draw detector problems only. See the

controller Operator’s Manual if the control ler exhibits any problems.

Fail Condition

Symptoms

• The sample-draw detector’s Fail LED is on.

• The monitoring device is operating properly but indicates a reading well below zero.

Probable causes

• The sample-draw detector’s flow rate is too low because of an obstructed sample line, failed pump, etc.

• The sample-draw detector is malfunctioning.

• The sensor wiring is disconnected or misconnected.

Recommended action

1. At the sample-draw detector, set the correct flow rate with the sensor flow control val ve.

2. If you cannot set the correct flow rate, check the sample lines for obstructions or kinks.

3. Verify that the sensor wiring is correct and secure. “Wiring the Combustible Gas Sample-Draw Detector to a Controller” on page 9 describes sensor wiring connections.

4. Calibrate the sample-draw detector as described in “Calibration” on page 16.

5. If the fail condition continues, replace the sensor as described in “Replacing the Infrared HC Sensor” on page 14.

6. If the fail condition continues, contact R KI Instruments, Inc. for further instruction.

Slow or No Response/Difficult or Unable to Calibrate

Symptoms

• The sensor responds slowly or does not respond during the monthly response test.

• Unable to accurately set the zero or response reading during the calibration procedure.

• The sensor requires fre quent calibration.

Probable causes

• The calibration cylinder is low, out-dated, or defective.

• If a demand flow regulator cal ibra tion kit i s used, t he deman d flow r egulator is not functi oning properly.

• The sample-draw detector’s flow rate is too low because of an obstructed sample line, failed pump, etc.

• The sample-draw detector is malfunctioning.

35-3001-01-02 Com b us ti b le Ga s Sample-Draw Det e ct or • 1 3

Recommended action

1. Verify that the calibration cylinder contains an adequate supply of a fresh test sample.

2. If a demand flow regulator calibration kit is used, use a different demand flow regulator to determine if the original one is functioning properly.

3. If necessary, set the correct flow rate with the sensor flow control valve.

4. If you cannot set the correct flow rate, check the sample line for obstructions or kinks.

5. If the calibration/response difficulties continue, replace the sensor as described later in this section.

6. If the calibration/response difficulties continue, contact RKI Instruments, Inc. for further instruction.

Replacing Components of the Combustible Gas Sample-Draw Detector

This section includes procedures to replace the sensor, hydrophobic filter, and particle filter.

Replacing the Infrared HC Sensor

1. Turn off the controller.

2. Turn off power to the controller.

3. Open the housing door of the sample-draw detector.

4. Unscrew and remove the four screws that secure the IR HC sensor PCB, then lift the IR HC sensor PCB and sensor off of the flow block.

There is a gasket at the bottom of the flow block. Be sure the gas ket stays in place.

5. Unplug the sensor from the IR HC sensor PCB.

6. Verify that you are using the correct replacement sensor, then plug the sensor into the IR HC sensor PCB.

7. Place the sensor and sensor PCB in the IR HC sensor cavity.

8. Secure the sensor PCB on the flow block with the four screws you removed in step 4.

9. Close and latch the housing door.

10. Turn on power to the controller.

11. Turn on the controller.

CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue.

12. Calibrate the replacement sensor as described in “Calibration” on page 16.

Replacing the Hydrophobic Filter

1. Open the housing door of the sample-draw detector.

2. Disconnect the filter from the rubber elbows on each end of the filter, then remove the filter from the sample-draw detector.

3. Install the new filter. Be sure the side of the filter marked “INLET” is connected to the elbow that is connected to the inlet fitting.

4. Verify that the flow rate is approximately 1.0 SCFH, then close the housing door.

14 • 35-3001-01-02 Combustible Gas Sample-Draw Detecto r

Replacing the Particle Filter

1. Disconnect the tubing routed to the sampling area, if installed, from the particle filter.

2. Disconnect the particle filter from the inlet fitting’s tubing stub.

3. Install the new particle filter onto the inlet fitting’s tubing stub. Be sure the arrow on the particle filter is pointing toward the inlet fitting.

4. Reinstall the tubing routed to the sampling area.

Adjusting the Low Flow Setting

NOTE: Adjusting the low flow setting will cause a low flow alarm at the sample-draw detector

and a fail alarm at the controller. Be sure to put the controller into its calibration program or disable external alarms before performing this test.

The factory-set low flow setting is 0.6 SCFH (±0.1). To adjust the low flow setting:

1. Use the sensor flow control valve to set the flow to 0.6 SCFH. Turn the valve’s knob counterclockwise to increase the flow and clockwise to decrease the flow.

If the sample-draw detector goes into low flow alarm before you can adjust the flow down to

0.6 SCFH, adjust the pressure switch adjustment screw 1/4 turn clockwise, then attempt to set the flow again. Repeat this step until you are able to adjust the flow to 0.6 SCFH.

NOTE: The pressure switch adjustment screw is accessible through a circular cutout in the

flowmeter circuit board.

2. Slowly turn the pressure switch adjustment screw counterclockwise just until the sample-draw detector goes into low flow alarm.

3. Turn the sensor flow control valve’s knob counterclockwise to increase the flow until the unit is out of low flow alarm.

4. Decrease the flow very slowly by turning the sensor flow control valve’s knob clockwise and verify that the low flow alarm is 0.6 SCFH (±0.1).

If the low flow alarm is set too low, turn the pressure switch adjustment screw slightly clockwise. Repeat steps 3 and 4 if necessary.

5. Use the sensor flow control valve to set the flow to 1.0 SCFH.

6. Make sure the sample-draw detector’s Fail LED is off.

Calibration Frequency

Although there is no particular calibration frequency that is correct for all applications, a calibration frequency of every 6 months is adequate for most infrared combustible gas transmitter applications. Unless experience in a particular application dictates otherwis e, RKI Instruments , Inc. recommends a calibration frequency of every 6 months.

If an application is not very demanding, for example detection in a clean, temperature controlled environment where calibration adjustments are minimal at calibration, then a c alibration freq uency of every 9 to 12 months is adequate.

If an application is very demanding, for example if the environment is not well controlled, then more frequent calibration than every 6 months may be necessary.

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Calibration

This section describes how to calibrate the combustible gas sample-draw detector. It includes procedures to prepare for calibration, set the zero reading, set the response reading, and return to normal operation.

NOTE: This procedure describes calibration using a demand flow regulator.

Prepari ng for Ca libration

1. Follow the instructions in the controller’s operator’s manual for entering calibration mode.

NOTE: If you can verify a fresh air environment, it is not necessary to us e the zero air calib ration

cylinder to set the zero reading.

2. Screw the regulator into a zero air calibration cylinder.

Setting the Zero Reading

1. Connect the sample tubing from the demand flow regulator to the sample-draw detector’s inlet line. This step is not necessary if you verified a fresh air environment earlier in this

procedure.

2. Allow the sample-draw detector to draw sample for one minute.

3. Follow the directions in the controller’s operator’s manual for setting the zero reading. If you used a zero air calibration cylinder to set the zero reading, proceed to step 4. If you verified a fresh air environment, proceed to the next section, Setting the Response Reading.

4. Disconnect the sample tubing from the inlet line.

5. Unscrew the regulator from the zero air calibration cylinder.

Setting the Response Reading

1. Screw the regulator into the combustible gas calibration cylinder.

2. Connect the sample tubing from the demand flow regulator to the sample-draw detector’s inlet line.

3. Allow the sample-draw detector to draw sample for one minute.

4. Follow the directions in the controller’s operator’s manual for setting the span.

5. Disconnect the sample tubing from the inlet line.

6. Unscrew the regulator from the combustible gas calibration cylinder.

Returning to Normal Operation

1. Wait appro ximately one minute to allow the combustible gas reading to stabilize.

2. Follow the instructions in the controller’s operator’s manual to exit the calibration mode.

3. Store the components of the calibration kit in a safe and convenient place.

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Parts List

Table 2 lists replacement parts and accessories for the combustible gas sample-draw detector.

Table 2: Parts List

Part Number Description

06-1248RK Sample tubing, 3/16 x 5/16, specify length 06-1248RK -03 Sample tubing, 3/16 x 5/16, 3 feet (for calibration kit) 07-0110RK Gasket for IR flow block 30-1016RK Pump 33-0165RK Hydrophobic filter 33-0167RK Particle filter 61-5039RK-HC Infrared HC sensor, plug-in type, %LEL range 71-0322RK Operator’s Manual, 35-3001-01-02 Sample-Draw Detector 81-0004RK-01 Calibration cylinder, 50% LEL propane in air, 34 liter 81-0004RK-03 Calibration cylinder, 50% LEL propane in air, 103 liter 81-0076RK-01 Zero air calibration cylinder (34 liter) 81-0076RK-03 Zero air calibration cylinder (103 liter) 81-1054RK Regulator, demand flow, for 58- and 103-liter cylinders 81-1055RK Regulator, demand flow, for 17- and 34-liter steel cylinders

35-3001-01-02 Com b us ti b le Ga s Sample-Draw Det e ct or • 1 7

RKI Instruments 35-3001-01-02 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual