RKI Instruments 35-3001-06-02 User manual

35-3001-06-02

Combustible Gas/Oxygen

Sample-Draw Detector

Operator’s Manual

Part Number: 71-0490
Revision: P1
Released: 3/13/19

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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.

35-3001-06-02 Combustible Gas/Oxygen Sample-Draw Detector

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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.

35-3001-06-02 Combustible Gas/Oxygen Sample-Draw Detector

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Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

External Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Connecting the Sample Lines to the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Wiring the Sample-Draw Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Introducing Incoming Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Replacing Components of the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Calibration, IR HC Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Calibration, Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Setting the Fresh Air Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

35-3001-06-02 Combustible Gas/Oxygen Sample-Draw Detector

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Overview

This operator’s manual describes the 35-3001-06-02 combustible gas/oxygen sample-draw
detector. This manual also describes how to install, start up, maintain, and calibrate the sample­draw 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/oxygen sample-draw detector. See the controller
Operator’s Manual for information specific to the controller.

Table 1: Specifications

Target Gases and Detection Range General hydrocarbons (calibrated to propane): 0 - 100% LEL

Oxygen: 0 - 25% volume

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

Flow to Sensor 1.0 SCFH (nominal)

Low Flow Setpoint 0.6 ± 0.1 SCFH

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

* RKI Instruments, Inc. does not recommend installing this tubing
size on both the inlet and exhaust.

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

Response Time 90% in 30 seconds

Accuracy Combustible Gas

± 5% of reading or ± 2% of full scale (whichever is greater)
Oxygen
± 0.5% O

Inlet

50 feet 0 feet

Inlet

50 feet 50 feet

75 feet 0 feet

:

:

2

Exhaust

Exhaust

W ARNIN G: When using the 35-3001-06-0 2, you mus t follow the ins tructi ons and warnin gs in

this manual to assure proper and safe operation of the 35-3001-06-02 and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 35-3001-06-02 as described in this manual.

35-3001-06-02 Combustible Gas/Oxygen Sample-Draw Detector • 5

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Description

Pump

O
X
Y
G
E
N

B

+

W

Oxygen
Sensor

Oxygen
Sensor
Terminal
Strip

IR HC S ensor
PCB

BG

Mounting

Foot, 4X

_

S

OXY

+

RS

IR HC S ensor
(inside block)

IR HC Flow
Block

+

+

AMP

AMP 2

Sensor F low

Control V alve

Fail LED

Pilot LED

BG

Interc onnect
Terminal
Strip

Pum p R eset

Switch

Flowmeter

Pressure Switc h

Adjustment Screw

(behind PCB)

OXY

GW

+

RS

AMP 2

+

AMP 1

+

S

This E nd To

Inlet Fitting

LEL/ IR

W

Particle Filter

LEL/ IR

W

Flowmeter Circuit

Board C onnector

Pump Connector

Oxygen Flow
Block

Exhaust

Fitting

Inlet

Fitting

3/4" C onduit Hub

EXHAUST

INLET

Hydrophobic

Filte r

Detector/Amp
Terminal Strip
(Factory Wired)

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

Figure 1: Combustible Gas/Oxygen Sample-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 for
installation where general purpose equipment is in use.

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The housing door is hinged on the left side and is secured by two latches on the right side. The

Oxygen

Sensor

Restrictor

Pump

Flowmeter

Particle Filter

Sensor Flow

Control Valve

Exhaust

Flowmeter PCB

IR HC

Sensor

Pressure Switch

Hydrophobi c Filter

Inlet

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 10 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 NPT 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: Combustible Gas/Oxygen Sample-Draw Detector Flow Diagram

35-3001-06-02 Combustible Gas/Oxygen Sample-Draw Detector • 7

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Main Circuit Board

The main circuit board includes the detector/amp terminal strip, interconnect terminal strip, oxygen
sensor terminal strip, pump connector, and flowmeter circuit board connector (see Figure 1).

Detector/Amp Terminal Strip

The detector/amp terminal strip is the upper twelve-point terminal strip in the bottom right corner
of the main circuit board. Use the detector/amp terminal strip to connect the combustible gas sensor
to the main circuit board.

NOTE: The combustible gas sensor is factory-wired to the main circuit board. See the

“Installation” section on page 10 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 terminal strip to connect the sample-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. Use the oxygen sensor terminal strip to connect the oxygen sensor to the main circuit
board.

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

section on page 10 for all wiring procedures related to 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 connector to connect the pump to the main circuit
board.

NOTE: The pump is factory-wired to the main circuit board. See “Installation” on page 10 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 10 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

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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 clockwise to
increase the flow and counterclockwise to decrease the flow.

Status LEDs

Two status LEDs are above the flowmeter. They are also visible through the window in the housing
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 18 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 Gas 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 HC flow block and the IR HC flow block is mounted to the
middle of the main circuit board. It is the lower of the two flow blocks mounted to the main circuit
board. A small circuit board, the IR HC sensor PCB, with 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.

Oxygen Sensor

The oxygen sensor is installed in a flow block and the flow block is mounted to the middle of the
main circuit board. It is the upper of the two flow blocks mounted to the main circuit board. The
oxygen sensor is retained in the flow block by a bracket with two screws.

The oxygen cell is protected within the sensor assembly. Through a series of chemical and
electronic reactions, the oxygen cell produces a millivolt output that is proportional to the detection
range of the sample-draw detector. The leads extending from the sensor terminate in lugs that
connect to the oxygen terminal strip.

35-3001-06-02 Combustible Gas/Oxygen Sample-Draw Detector • 9

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Installation

Ø.30x.50(4X)MOUNTING

.78

1.13

.40

Pilot Fail

.85

.80

4.50

NOTE: Housing is4.3 inchesdeep

8.88

4.00

6.50

35-3001

www.rkiinstruments.com

Sa m p le Drawin g

Gas Detector

8.50

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 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 wiring and tubing connections 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?

Figure 3: Outline and Mounting Dimensions

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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 vertical 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.

Connecting the Sample Lines to the Sample-Draw Detector

See Figure 5 for the fitting layout.

Installing the Inlet Line with Particle Filter Connected to the Inlet Fitting

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

2. Push the particle filter’s tubing stub into the inlet fitting until it stops. Be sure the arrow on the
particle filter is pointing toward the inlet fitting.

3. Hand tighten the nut on the inlet fitting so the ferrules clamp on the tubing. If the tube nut is
removed, see Figure 5 for the arrangement of the fitting components.

4. 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. recommends 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 5 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 sa mple line. To reduce response time, keep the

incoming sample line as short as possible.

Installing the Inlet Line without Particle Filter Connected to the Inlet Fitting

1. Loosen the nut on the inlet 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. tubing based on your
length requirements. See “Specifications” on page 5 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.

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3. Hand tighten the nut on the inlet fitting so the ferrules clamp on the tubing. If the tube nut is
removed, see Figure 5 for the arrangement of the fitting components.

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

CAUTION: Avoid lo ops or slumps in the incoming sa mple line. To reduce response time, keep the

incoming sample line as short as possible.

5. If desired, install the particle filter onto the end of the inlet line. Be sure the arrow on the
particle filter is pointed toward the inlet line.

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. tubing based on your
length requirements. See “Specifications” on page 5 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 5 for the arrangement of the fitting components.

4. Route the opposite end of the tubing to an open area where the sample can safely disperse or to
an exhaust duct. See “Specifications” on page 5 for maximum tubing lengths based on tubing
size.

Wiring the 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 eight-conductor, shielded cable or eight wires in conduit through the conduit hub at the
bottom of the sample-draw housing. A minimum of 18 AWG wire is recommended.

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

4.

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.

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8. Connect the wires to the applicable detector/transmitter terminal strip at the controller as

OXY

Controller Detector/
Transmitter Termi nal
Strip, LEL Detector
Terminals

White

Green

Black

Red

LEL/IR

PATS101PATS101PATS201PATS201

LEL/IR

OXY

Black
Green
White
Red

AMP 1

Black (-)

White (+)

AMP 1

AMP 2

Controller Detector/

Transmitter Term inal

Strip Terminals

White

Green

Controller Detector/Transm itter

Terminal Strip, Oxygen

DetectorTerminals

- (DC Ground)

+ 24 VDC

Oxygen

Sensor

IR HC

Sensor PCB

AMP 2

shown in Figure 4. Refer to the controller operator’s manual and the controller detector head
specification sheet for the 35-3001-06-02 for detector/terminal strip connections specific to the
controller.

Figure 4: Wiring the Sample-Draw Detector to a Controller

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.

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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 manual.

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 controller.

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 clockwise to
increase the flow and counterclockwise 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 or an a bnorma l oxygen concentra tion

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, IR H C S e ns or” o n pa ge 20 and “Calibration, Oxygen Sensor” on
page 21 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 environment (environment known
to be free of combustible gas and of normal oxygen concentration, 20.9%).

2. Verify a reading of 0 %LEL for the combustible channel and 20.9% for the oxygen channel on
the controller display screen for the applicable channel.

If the display reading is 0 %LEL for the combustible channel and 20.9% for the oxygen
channel, start up is complete. The sample-draw detector is in normal operation. If the display

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3. Perform a zero (fresh air) operation at the controller. See “Setting the Zero Reading” on

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, adjust the low flow setting, and remove the particle
filter’s tubing stub.

Preventive Maintenance

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

reading is not 0 %LEL for the combustible channel or 20.9% for the oxygen channel, continue
with step 3.

page 20 (for IR HC sensor), “Setting the Fresh Air Reading” on page 21 (for oxygen sensor),
and the controller operator’s manual for instructions to perform a zero (fresh air) operation.

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

3. Verify a display reading of 0 %LEL for the combustible channel and 20.9% for the oxygen
channel at the controller. Investigate significant changes in the display reading.

Quarterly Calibration

Calibrate the oxygen sensor as described in “Calibration, Oxygen Sensor” on page 21.

Biannual Calibration

Calibrate the IR HC sensor as described in “Calibration, IR HC Sensor” on page 20.

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 controller 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.

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Recommended action

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

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 Sample-Draw Detector to a
Controller” on page 12 describes sensor wiring connections.

4. Calibrate the sample-draw detector as described in “Calibration, IR HC Sensor” on page 20
and “Calibration, Oxygen Sensor” on page 21.

5. If the fail condition continues, replace the sensor(s) as described in “Replacing Components of
the Sample-Draw Detector” on page 16.

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

Slow or No Response/Difficult or Unable to Calibrate

Symptoms

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

• The sensor requires frequent calibration.

Probable causes

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

• If a demand flow regulator calibration kit is used, the demand flow regulator is not functioning
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.

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 Sample-Draw Detector

This section includes procedures to replace the IR HC gas sensor, oxygen sensor, hydrophobic
filter, and particle filter.

Replacing the IR HC Gas 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 gasket stays in place.

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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 combustible gas 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, IR HC Sensor” on page 20.

Replacing the Oxygen Sensor

1. Turn off the controller.

2. Turn off power to the controller.

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

4. Loosen the two screws on the oxygen terminal strip and remove the lugs and wires from the
terminal strip.

5. Unscrew and remove the two screws that secure the sensor retaining plate, then lift the plate
and sensor out of the flow block.

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

6. Place the replacement sensor in the oxygen flow block, then position the retaining plate on the
two standoffs.

7. Secure the retaining plate to the standoffs with the two screws you removed in step 4.

8. Guide the wires and lugs of the replacement sensor to the oxygen terminal strip and insert each
lug into the appropriate terminal. See Figure 4 on page 13 for wiring connections. Tighten the
screws on the terminal strip.

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, Oxygen Sensor” on page 21.

Replacing the Hydrophobic Filter

1. Turn off the controller.

2. Turn off power to the controller.

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

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

5. 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.

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6. Turn on power to the controller.

7. Turn on the controller.

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

Replacing the Particle Filter

1. Turn off the controller.

2. Turn off power to the controller.

3. If the particle filter is installed at the inlet fitting:

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

2. Disconnect the particle filter from the tubing stub.

3. Install the new particle filter onto the 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.

4. If the particle filter is installed at the end of the inlet line:

1. Remove the particle filter from the tubing stub.

2. Install the new particle filter onto the tubing stub. Be sure the arrow on the particle filter is

pointing toward the inlet line.

5. Turn on power to the controller.

6. Turn on the controller.

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 clockwise
to increase the flow and counterclockwise 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 clockwise to increase the flow until the unit is out of
low flow alarm when the reset switch is pressed and released.

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

If the low flow alarm is set too high, 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.

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

Outside of Case

Fitting Body

Front Ferrule

Back Ferrule

1/4" Tube

1/4" Tube

O-ring

Tube Nut

Inside of Case

Removing the Particle Filter’s Tubing Stub, if Necessary

A short tubing stub comes factory installed in the particle filter. It is used for connecting the particle
filter to the inlet fitting. If you have installed the particle filter and no longer want it installed, you
will need to remove the particle filter’s tubing stub from the inlet fitting and replace it with tubing.

Figure 5: Inlet Fitting with Tubing Stub

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

1. Remove the particle filter from its tubing stub.

2. 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.
If you do lose the O-ring or if it is damaged, see “Parts List” on page 23 for the spare part
number.

3. Push the tubing stub up and out of the front ferrule being careful not to lose the ferrule set. If
you do lose the ferrule set or if it is damaged, see “Parts List” on page 23 for the spare part
numbers.

4. Push the new tubing up through the inlet fitting tube nut and replace the ferrule set and the O­ring, if it came out, in the orientation shown in Figure 5.

5. Screw the inlet fitting tube nut back onto the fitting body. See “Connecting the Sample Lines to
the Sample-Draw Detector” on page 11 for instructions to install a new piece of tubing into the
fitting.

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Calibration Frequency

Although there is no particular calibration frequency that is correct for all applications, a calibration
frequency of every 3 months is adequate for most sample draw detector applications. Unless
experience in a particular application dictates otherwise, RKI Instruments, Inc. recommends a
calibration frequency of every 3 months for the oxygen detector and every 6 months for the infrared
HC detector.

If an application is not very demanding, for example detection in a clean, temperature controlled
environment, and calibration adjustments are minimal at calibration, then a calibration frequency of
every 6 months is adequate for the oxygen detector and every 9 to 12 months is adequate for the
infrared HC detector.

If an application is very demanding, for example if the environment is not well controlled, then
more frequent calibration than every 3 months for the oxygen detector and every 6 months for the
infrared HC detector may be necessary.

Calibration, IR HC Sensor

This section describes how to calibrate the IR HC gas sensor of the 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.

Preparing for Calibration

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 use the zero air calibration

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.

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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 approximately 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.

Calibration, Oxygen Sensor

This section describes how to calibrate the oxygen sensor in the sample-draw detector. It includes
procedures to prepare for calibration, set the fresh air reading, set the zero reading, and return to
normal operation.

NOTE: Calibrating the sample draw detector may cause alarms. Be sure to put the controller into

its calibration program or disable external alarms before continuing.

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

Preparing for Calibration

NOTE: If you can verify a fresh air environment, it is not necessary to use a zero air calibrating

sample to set the fresh air reading at the controller.

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

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

Setting the Fresh Air Reading

1. Connect the sample tubing from the demand flow regulator to the sample-draw detector’s inlet
fitting. 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 fresh air reading.

4. Disconnect the sample tubing from the inlet fitting.

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

Setting the Zero Reading

1. Screw the demand flow regulator onto the 100% N2 calibration cylinder.

2. Connect the sample tubing from the regulator to the inlet line.

3. Allow the sample-draw detector to draw the calibrating sample for 1 minute.

4. Follow the directions in the controller’s operator’s manual for setting the zero (oxygen free)
reading.

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5. Disconnect the sample tubing from the sample-draw detector’s inlet fitting.

6. Reconnect the incoming sample line to the inlet fitting.

7. Unscrew the regulator from the calibration cylinder.

Returning to Normal Operation

1. Wait 1 to 2 minutes to allow the oxygen reading at the controller to return to normal, then
return the controller to normal operation.

NOTE: If you do not allow the oxygen reading to return to normal, then unwanted alarms may

occur.

2. Verify that the controller display reading stabilizes at 20.9%.

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

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Parts List

Part Number Description

06-1248RK Sample tubing, 3/16” ID x 5/16” OD, specify length

06-1248RK-03 Sample tubing, 3/16” ID x 5/16” OD, 3 feet (for calibration kit)

07-0053RK Gasket for oxygen flow block

07-0110RK Gasket for IR flow block

17-2670 Inlet fitting O-ring

17-2671 Inlet fitting front ferrule

17-2672 Inlet fitting back ferrule and tube nut

30-1016RK Pump

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

Table 2: Parts List

33-0165RK Hydrophobic filter

33-0167RK Particle filter

61-5039RK-HC Infrared HC sensor, plug-in type, %LEL range

71-0490 Operator’s Manual, 35-3001-06-02 Sample-Draw Detector

81-0004RK-01 Calibration cylinder, 50% LEL propane in air, 34 liter steel

81-0004RK-03 Calibration cylinder, 50% LEL propane in air, 103 liter

81-0076RK-01 Zero air calibration cylinder, 34 liter steel

81-0076RK-03 Zero air calibration cylinder, 103 liter

81-0078RK-01 Calibration cylinder, 100% nitrogen, 34 liter steel

81-0078RK-03 Calibration cylinder, 100% nitrogen, 103 liter

81-1054RK Regulator, demand flow, for 34 liter aluminum, 58 liter, and 103 liter calibration

cylinders (cylinders with internal threads)

81-1055RK Regulator, demand flow, for 17 liter and 34 liter steel calibration cylinders

(cylinders with external threads)

OS-B11 Oxygen sensor

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