RKI Instruments 35-3001-01H-DIL, 35-3001-06H-DIL Operator's Manual

35-3001-01H-DIL

Hydrogen Sample-Draw Detector

Operator’s Manual

Part Number: 71-0381
Revision: A
Released: 8/3/17

www.rkiinstruments.com

WARNING

Read and understand this instruction manual before operating
detector. Improper use of the detector 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.
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.

35-3001-01H-DIL Hydrogen Sample-Draw Detector

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 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 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:

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 W ARRAN T Y 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 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.

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.

35-3001-01H-DIL Hydrogen Sample-Draw Det ect or

Table of Contents

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

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

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

External Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Wiring the 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 Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

35-3001-01H-DIL Hydrogen Sample-Draw Detector

Overview

This operator’s manual describes the 35-3001-01H-DIL hydrogen 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.

About the 35-3001-01H-DIL

The 35-3001-01H-DIL is designed to monitor hydrogen in an inerted area (an area that has no, or
almost no, oxygen present). The catalytic LEL sensor used to detect hydrogen must have at least
5% oxygen present to detect gas properly. A dilution fitting installed in the flow system before the
LEL sensor allows enough air to enter the gas sample so that the LEL sensor has enough oxygen to
function properly. The dilution ratio is approximately 1:1 but will vary slightly with increased
sample line lengths. The longer the sample line, the more dilution air will enter the gas sample
through the dilution fitting. Because of this, it is important when calibrating the detector head to
apply the calibration gas to the sample line inlet if a sample line is installed. In addition, because
the detector head includes internal dilution, it must be calibrated using a sample bag instead of a
demand flow regulator. See “Calibration” on page 18 for detailed calibration instructions.

Specifications

Table 1 lists specifications for the hydrogen sample-draw detector. See the controller Operator’s
Manual for information specific to the controller.

Table 1: Specifications

Target Gases and Detection Range Hydrogen: 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

Weight 4.5 lbs.

Sampling Method Sample-draw

Sample Flow 3.0 SCFH typical, with no inlet or exhaust line

Low Flow Setpoint 1.0 ± 0.1 SCFH, measured in the sample inlet line

Sensor Flow 0.8 SCFH (nominal)

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

Inlet

100 feet 0 feet

50 feet 50 feet

Exhaust

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

Response Time 90% in 30 seconds

Inlet

100 feet 100 feet

35-3001-01H-DIL Hydrogen Sample-Draw Detecto r • 1

Exhaust

Table 1: Specifications

Accuracy ± 5% of reading or ± 2% LEL (whichever is greater)

WAR NING: When using the 35-3001-01H-DIL, you must follow the instructions and

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

2 • 35-3001-01H-DIL Hydrogen Sample-Draw Detector

Description

O
X
Y
G
E
N

B

+

W

Oxygen
Sensor
Terminal
Strip

Pump

LEL Sensor

Dilution
Fitting

W BG

LEL Flow
Block

_

AMP 2SOXY

+

S

+

+

AMP

Sensor Flow

Control Valve

Fail LED

Pilot LED

Pressure

Switch

Adjustment

Screw

(behind PCB)

Flowmeter

W BG

Interconnect
Terminal
Strip

Pump Reset

Switch

OXY

GW

+

+

AMP 1

S

+

S

AMP 2

Hydrophobic

Filter

LEL/ IR

R

R

Flowmeter Circuit

Board Connec tor

Pump Connector

LEL/ IR

3/4" Conduit Hub

Particle Filter

Exhaust

Fitting

Inlet

Fitting

This End To
Inlet Fitting

Mounting

Foot, 4X

EXHAUST

INLET

Detector/Amp
Terminal Strip
(Factory
Wired)

This section describes the components of the hydrogen sample-draw detector.

Figure 1: Hydrogen Sample-Draw Detector Component Location

35-3001-01H-DIL Hydrogen Sample-Draw Detecto r • 3

External Components

LEL

Sensor

Flowmeter

Hydrophobic Filter

Pump

Exhaust

Pressure Sw itch

Flowmeter PCB

Sensor Flow

Contr ol Val v e

Restrictor

Inlet

Dilution Fitting,

appr ox. 1:1 ratio

Particle Filter

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 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.

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 sample fittings
accept 1/4 in. rigid tubing. See the Installation section on page 7 to connect tubing to the sample
fittings.

Particle Filter

A particle filter with a tubing stub on one end is shipped with the instrument but it is not factory
installed. If the particle filter is installed directly to the inlet fitting, the tubing stub must be used. If
the particle filter is installed somewhere else, like at the end of the inlet line, the tubing stub can be
used or removed.

Conduit Hub

One 3/4” conduit hub is located on the right side of the bottom of the housing. It is used for 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.

Figure 2: Hydrogen Sample-Draw Detector Flow Diagram

4 • 35-3001-01H-DIL Hydrogen Sample-Draw Detector