RKI Instruments 35-3001-13 Series, 35-3001-13-02, 35-3001-13-03, 35-3001-13-10, 35-3001-13-05 Operator's Manual

35-3001-13-XX

Carbon Dioxide/Oxygen

Sample-Draw Detector

Operator’s Manual

Part Number: 71-0506

Revision: P1

Released: 9/10/19

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.

35-3001-13-02 Carbon Dioxide/Oxygen 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 WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES
AND REPRESENTATIONS, EXPRESSED OR IMPLIED, AND ALL OTHER
OBLIGATIONS OR LIABILITIES ON THE PART OF RKI INSTRUMENTS, INC.
INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS,
INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL LOSS OR
DAMAGE OF ANY KIND CONNECTED WITH THE USE OF ITS PRODUCTS OR
FAILURE OF ITS PRODUCTS TO FUNCTION OR OPERATE PROPERLY.

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.

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw Detector

Table of Contents

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

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

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Internal Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mounting the Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Connecting the Sample Lines to the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring the Sample-Draw Detector to a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Replacing Components of the Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Calibration, IR CO2 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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

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

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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

Calibration, Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

Overview

This operator’s manual describes the 35-3001-13-XX carbon dioxide/oxygen 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 sample­draw detector.

Specifications

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

Table 1: Specifications

Target Gases and Detection Range Carbon

Dioxide
(CO

)

2

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.

35-3001-13-02: 0 - 5,000 ppm (parts per million)
35-3001-13-03: 0 - 5% volume
35-3001-13-05: 0 - 50% volume
35-3001-13-10: 0 - 100% volume

Inlet

50 feet 0 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

Accuracy Carbon Dioxide

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

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw Det ec to r • 5

Inlet

50 feet 50 feet

75 feet 0 feet

:

:

2

Exhaust

WARNING: When using the 35-3001-13-XX, you must follow the instructions and warnings in this manual

to assure proper and safe operation of the 35-3001-13-XX and to minimize the risk of personal
injury. Be sure to maintain and periodically calibrate the 35-3001-13-XX as described in this
manual.

6 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

Description

Figure 1: Component Location

Pump

O
X
Y
G
E
N

B

+

W

Oxygen
Sensor

Oxygen
Sensor
Term inal
Strip

IR CO2 Sensor
PCB

BG

Mounting

Foot, 4X

_

S

OXY

+

RS

IR CO2 Flow
Block

IR CO2 Sensor
(inside b lock)

+

+

AMP

AMP 2

Sensor Flow

Con trol V alve

Fail LED

Pilot LED

BG

In terc onne ct
Term inal
Strip

Pump Reset

Switch

Flowm eter

Pressure Switch

Adjustment Scr ew

(be hind PCB)

OXY

GW

+

RS

AMP 2

+

AMP 1

+

S

This E nd T o

Inlet Fitting

LEL/ IR

W

Particle Filter

LEL/ IR

W

Flowme ter C ircuit

Board Connector

Pump Connector

OxygenFlow
Block

Exhaust

Fitting

Inlet

Fitting

3/ 4" C ond uit H ub

EXHAUST

INLET

Hydrophobic

Filter

Detec tor/Am p
Termi nal S tri p
(F acto ry W ir ed)

This section describes the components of the carbon dioxide/oxygen sample-draw detector.

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.

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw Det ec to r • 7

Flowmeter

Pump

Restrictor

Oxygen

Sensor

Particle Filter

Flowmeter PCB

Exhaust

Sensor Flow

Control Valve

IR CO2
Sensor

Hydrophobic Filter

Pressure Switch

Inlet

Figure 2: Flow Diagram

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 11 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.

8 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

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 carbon dioxide sensor to the main circuit board.

NOTE: The carbon dioxide sensor is factory-wired to the main circuit board. See the “Installation” section on

page 11 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 11

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 11 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 11 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 clockwise to increase the flow and
counterclockwise to decrease the flow.

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw Det ec to r • 9

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 19 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 sample­draw detector. The pump operates on 24 VAC, which is generated from the 24 VDC supplied by the controller.

IR CO

The CO

IR CO
mounted to the main circuit board. A small circuit board, the IR CO

the IR CO

Gas Sensor/IR CO2 Sensor PCB

2

sensor is an infrared type plug-in sensor. The IR CO2 sensor is installed in the IR CO2 flow block. The

2

flow block is mounted to the middle of the main circuit board. It is the lower of the two flow blocks

2

sensor PCB, with a 4-wire cable mates to

2

sensor and retains it in the flow block. The cable is wired to the main PCB. The IR CO2 sensor PCB

2

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.

10 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

Installation

Figure 3: Outline and Mounting Dimensions

Ø .30 x .50 (4X) MOUNTING

.78

1.13

.40

Pilot Fail

.85

.80

4.50

NOTE: Ho using is4.3 inches deep

8.88

4.00

6.50

35-3001

www.rkiinstruments.com

Sa mpl e Dr awing

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?

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw D et ec to r • 11

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 loops or slumps in the incoming sample 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.

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.

12 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

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 loops or slumps in the incoming sample 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.

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw D et ec to r • 13

Figure 4: Wiring to a Controller

PATS201

LEL/IR

OXY

White

Green

Black

Red

LEL/IR

PATS101PATS101PATS201

OXY

Black
Green
White
Red

AMP 1

Black (-)

White (+)

AMP 1 AMP 2

Controller Detector/

Transmitter Terminal

Strip Terminals

White

Green

Controller Detector/Transmitter

Terminal Strip, Oxygen

DetectorTerminals

- (DC Ground)

+ 24 VDC

Oxygen

Sensor

Controller Detector/
Transmitter Terminal
Strip, LEL Detector
Terminals

IR CO2

Sensor PCB

AMP 2

8. Connect the wires to the applicable detector/transmitter terminal strip at the controller as shown in Figure 4.
Refer to the controller operator’s manual and the controller detector head specification sheet for the

35-3001-13-XX for detector/terminal strip connections specific to the 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.

14 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

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

Since there is a background of CO2 in air of typically 300 - 600 ppm (0.03 - 0.06% volume), it is necessary to use
a calibration kit with a 100% nitrogen cylinder to set the zero signal for the 0 - 5,000 ppm and 0 - 5% volume

versions. Fresh air can be used to set the zero signal for the 0 - 50% and 0 - 100% volume versions.

1. Verify that the sample-draw detector is sampling a fresh air environment with 20.9% oxygen. If the detector
is not sampling a fresh air environment, see “Setting the Fresh Air Reading” on page 22 for instructions to
apply zero air.

2. Verify a reading of 20.9% for the oxygen channel on the controller display.

If the display reading is 20.9% for the oxygen channel, start up is complete. The sample-draw detector is in
normal operation. If the display reading is not 20.9% for the oxygen channel, continue with step 3.

3. Perform a fresh air operation at the controller. See “Setting the Fresh Air Reading” on page 22, and the
controller operator’s manual for instructions to perform a fresh air operation.

4. Since there is a background of CO

to use a calibration kit with a 100% nitrogen cylinder to set the zero signal for the 0 - 5,000 ppm and 0 - 5%
volume CO

sensors.

sensors. Fresh air can be used to set the zero signal for the 0 - 50% and 0 - 100% volume

2

in air of typically 300 - 600 ppm (0.03 - 0.06% volume), it is necessary

2

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw D et ec to r • 15

5. Screw the demand flow regulator into the 100% nitrogen calibration cylinder.

6. Connect the calibration tubing from the demand flow regulator to the inlet fitting. Gas will begin to flow.

7. Allow the detector to draw sample for one minute.

8. Verify a reading of 0 ppm or 0% vol for the carbon dioxide channel on the controller display.

9. If the display reading is 0 ppm or 0% vol for the carbon dioxide channel, start up is complete. The sample­draw detector is in normal operation. If the display reading is not 0 ppm or 0% vol, continue with step 5.

10. Perform a zero operation at the controller. See “Setting the Zero Reading” on page 21 and the controller
operator’s manual for instructions to perform a zero operation.

11. Remove the calibration tubing from the inlet fitting, then reconnect the sample tubing to the inlet fitting.

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 sample­draw 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 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. For the carbon dioxide channel: Verify a display reading at the controller of the background concentration of
CO

. Typical background concentrations of CO2 vary from about 300 to 600 ppm (0.03 - 0.06% volume)

2

depending on location. The 0 - 5,000 ppm and 0 - 5% volume ranges will show a reading in fresh air. The
0 - 50% and 0 - 100% volume ranges should not show a reading in fresh air. Investigate significant changes
in the display reading.

4. For the oxygen channel: Verify a display reading of 20.9% at the controller. Investigate significant changes
in the display reading.

Quarterly Calibration

Calibrate the oxygen sensor as described in “Calibration, Oxygen Sensor” on page 22.

Biannual Calibration

Calibrate the IR CO

sensor as described in “Calibration, IR CO2 Sensor” on page 21.

2

16 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

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.

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 13 describes sensor wiring connections.

4. Calibrate the sample-draw detector as described in “Calibration, IR CO

Sensor” on page 21 and

2

“Calibration, Oxygen Sensor” on page 22.

5. If the fail condition continues, replace the sensor(s) as described in “Replacing Components of the Sample­Draw Detector” on page 18.

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.

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw D et ec to r • 17

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 CO2 gas sensor, oxygen sensor, hydrophobic filter, and

particle filter.

Replacing the IR CO

Gas Sensor

2

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 CO

sensor PCB, then lift the IR CO2 sensor PCB

2

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.

5. Unplug the sensor from the IR CO

sensor PCB.

2

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

7. Place the sensor and sensor PCB in the carbon dioxide 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 CO

Sensor” on page 21.

2

Replacing the Oxygen Sensor

sensor PCB.

2

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 14 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.

18 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

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 22.

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.

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:

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

b. Disconnect the particle filter from the tubing stub.

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

toward the inlet fitting.

d. Reinstall the tubing routed to the sampling area.

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

a. Remove the particle filter from the tubing stub.

b. 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.

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw D et ec to r • 19

Figure 5: Inlet Fitting with Tubing Stub

Outside of Case

Fitting Body

Front Ferrule

Back Ferrule

1/4" Tube

1/4" Tube

O-ring

Tube Nut

Inside of Case

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 slowly by 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.

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

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.

20 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

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 24 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 24 for the spare part numbers.

4. Push the new tubing up through the inlet fitting tube nut and replace the ferrule set and the O-ring, 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 Sample­Draw Detector” on page 12 for instructions to install a new piece of tubing into the fitting.

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 CO

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 CO

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 CO

necessary.

detector.

2

detector.

2

detector may be

2

Calibration, IR CO2 Sensor

This section describes how to calibrate the IR CO2 sensor. 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.

Setting the Zero Reading

Since there is a background of CO2 in air of typically 300 - 600 ppm (0.03 - 0.06% volume), it is necessary to use
a calibration kit with a 100% nitrogen cylinder to set the zero signal for the 0 - 5,000 ppm and 0 - 5% volume

versions. Fresh air can be used to set the zero signal for the 0 - 50% and 0 - 100% volume versions.

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

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.

4. Disconnect the sample tubing from the inlet line.

5. Unscrew the regulator from the 100% nitrogen calibration cylinder.

Setting the Response Reading

1. Screw the regulator into the carbon dioxide 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.

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw D et ec to r • 21

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 carbon dioxide calibration cylinder.

Returning to Normal Operation

1. Wait approximately one minute to allow the carbon dioxide 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. 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.

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.

22 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

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.

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw D et ec to r • 23

Parts List

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

Table 2: 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

33-0165RK Hydrophobic filter

33-0167RK Particle filter

61-5040RK-02 Infrared carbon dioxide sensor, 0 - 5,000 ppm range

61-5040RK-03 Infrared carbon dioxide sensor, 0 - 5% vol range

61-5040RK-05 Infrared carbon dioxide sensor, 0 - 50% vol range

61-5040RK-10 Infrared carbon dioxide sensor, 0 - 100% vol range

71-0506 Operator’s Manual, 35-3001-13-XX Sample-Draw Detector

81-0070RK-01 Calibration cylinder, 2000 ppm CO

81-0070RK-03 Calibration cylinder, 2000 ppm CO

81-0072RK-01 Calibration cylinder, 2.5% CO

81-0072RK-03 Calibration cylinder, 2.5% CO

81-0073RK-01 Calibration cylinder, 15% CO

81-0073RK-03 Calibration cylinder, 15% CO

in nitrogen, 34 liter steel

2

in nitrogen, 103 liter

2

in nitrogen, 34 liter steel

2

in nitrogen, 103 liter

2

in nitrogen, 34 liter steel

2

in nitrogen, 103 liter

2

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)

24 • 35-3001-13-02 Carbon Dioxide/Oxygen Sample-Draw Detector

Table 2: Parts List

Part Number Description

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

(cylinders with external threads)

OS-B11 Oxygen sensor

35-3001-13-02 Ca rb on Dioxide/Oxygen Sample-Draw D et ec to r • 25