RKI Instruments 35-3001A-01H User manual

35-3001A-01H

Hydrogen Sample-Draw Detector

Operator’s Manual

Part Number: 71-0307RK
Revision: A
Released: 8/7/17

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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.

35-3001A-01H Hydrogen 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.

35-3001A-01H Hydro gen Sample-Draw Detecto r

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Table of Contents

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

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

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

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

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

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

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

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

Wiring the Hydrogen Sample-Draw Detector to a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

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

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

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

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

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

Replacing Components of the Hydrogen Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

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

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

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

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

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

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

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

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

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Overview

This operator’s manual describes the 35-3001A-01H hydrogen sample-draw detector. This manual
also describes how to install, start up, maintain, and calibrate the sample-draw detector when using
it with a gas monitoring controller. A parts list at the end of this manual lists replacement parts and
accessories for the sample-draw detector.

Specifications

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

Target Gas and Detection Range Hydrogen: 0 - 100% LEL

Input Power 24 VDC Nominal (18.5 VDC - 30 VDC)

Construction (housing) Fiberglass/polyester (NEMA 4X)

Dimensions 8.5 in. H x 6.5 in. W x 4.25 in. D

Table 1: Specifications

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

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

Response Time 90% in 30 seconds

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

W ARNING: When using the 35-3001A-01H, you must follow the instructions and warnings in

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

Inlet

100 feet 0 feet

50 feet 50 feet

Inlet

100 feet 100 feet

Exhaust

Exhaust

35-3001A-01H Hydro gen Sample-Draw Det ector • 1

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Description

Pump

Oxygen
Sensor
Terminal
Strip

Mounting
Foot, 4X

W

+

B

O
X
Y
G
E
N

_

S

PWR/SIG

Hydrogen
Flow
Block

Pilot LED

Fail LED

Sensor Flow

Control Valve

Interconnect
Terminal
Strip

Pump R eset

Switch

Flowmeter

WS

+

AMP1

+

AMP2

OXY

S R

+

WG

G

Hydrophobic

Filter

Particle
Filter

B

LEL/ IR

Flowmeter Circuit

Board Connector

Inlet

Fitting

Exhaust

Fitting

This End
To Inlet
Fitting

3/4" Conduit Hub

Hydrogen
Sensor

INLET

EXHAUST

Pump C onnector

Hydrogen Amplifier

Sensor
Current

115mA

W

LEL

GBR

AMP2AMP

+

+

W B

Pressure

Switch

Adjustment

Screw

(behind PCB)

Detector/Amp
Terminal Strip
(Factory
Wired)

LEL/ IR

GS R

+

OXY

S

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

Figure 1: Hydrogen Sample-Draw Detector Component Location

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External Components

Flowmeter

Pump

Hydrogen

Sensor

ParticleFilter

Exhaust

Flowmeter PCB

Hydrophobic Filter

Pressure Switch

Restrictor

Inlet

Sensor

Flow

Control

Valve

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

Housing

The sample-draw detector’s fiberglass housing is weather- and corrosion-resistant. It is suitable for
installation where general purpose equipment is in use.

The housing door is hinged on the left side and is secured by two latches on the right side. The
flowmeter and status LEDs are visible through a window in the housing door.

Four mounting feet are attached to the back of the housing (one at each corner). Use the mounting
feet to install the housing to a vertical surface.

Sample Fittings

The sample fittings are located on the left side of the bottom of the housing. The inlet fitting is near
the front of the housing and the exhaust fitting is near the back of the housing. The sample fittings
accept 1/4 in. rigid tubing. See the Installation section on page 7 to connect tubing to the sample
fittings.

Particle Filter

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

Conduit Hub

One 3/4” conduit hub is located on the right side of the bottom of the housing. It is used for routing
wiring into the housing by using conduit or an appropriate cable bushing.

Internal Components

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

Figure 2: Hydrogen Sample-Draw Detector Flow Diagram

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35-3001A-01H Hydro gen Sample-Draw Det ector • 3

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 amplifier to the main
circuit board.

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

page 7 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. This terminal strip is not used in this version of the sample-draw detector.

Pump Connector

The pump connector is the two-point connector below the oxygen terminal strip in the upper right
corner of the main circuit board. Use the pump 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 7 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 7 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

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counterclockwise to increase the flow and clockwise 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 16 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.

Hydrogen Sensor

The catalytic hydrogen sensor detects hydrogen in the %LEL range. It uses a catalytic element for
detection. The reaction of gas with oxygen on the catalyst causes a change in the resistance of the
element which changes the current flowing through it. The current is proportional to the detection
range of the sample-draw detector.

The hydrogen sensor is installed in the flow block and the flow block is mounted to the middle of
the main circuit board. The sensor housing includes a sintered metal flame arrestor on one end that
allows gas to diffuse into the sensor. The sensor has a built in molecular sieve that only allows
hydrogen to diffuse into the detector. On the other end, five pins extend from the sensor and plug
into the socket connector. The connector allows you to replace the sensor without disconnecting the
wiring. Four leads extending from the connector are factory wired to the amplifier.

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Amplifier

S

PWR / SIG

Zero Pot

Span Pot

Controller
Terminal Strip

Detector

Terminal Strip

Test Points

100-500 mV Range

Factory Set Pots

W

LEL

G

BR

The amplifier converts the electrical output from the detector to a 4 to 20 mA signal that
corresponds to the detection range and transmits the signal to a gas monitoring controller. A label
on the amplifier indicates the detector drive current. This drive current is factory set and is dictated
by the combustible gas to which the detector is calibrated. Consult RKI Instruments, Inc. if you
plan to change the calibration gas for the sample-draw detector, for example from a hydrogen
calibration to a methane calibration. The amplifier is mounted on the top middle edge of the main
circuit board. It consists of the zero pot, span pot, controller terminal strip, detector terminal strip,
and test points.

Figure 3: Amplifier Component Location

Zero Pot

The zero pot is located in the upper right corner of the amplifier (see Figure 3). Use a small flat
blade screwdriver to turn the zero pot’s adjustment screw and adjust the amplifier’s zero (fresh air)
output during the start-up and calibration procedures. Turn the adjustment screw clockwise to
increase the fresh air output and counterclockwise to decrease the fresh air output.

Span Pot

The span pot is located below the zero pot (see Figure 3). Use a small flat blade screwdriver to turn
the span pot’s adjustment screw and adjust the amplifier’s gas response output during the
calibration procedure. Turn the adjustment screw clockwise to increase the span output and
counterclockwise to decrease the span output.

CAUTION: The amplifier includes additional pots. They are factory-set. Do not adjust them.

Controller and Detector Terminal Strips

The controller terminal strip and detector terminal strip are three- and four-position plug-in style
terminal strips, respectively. The controller terminal strip is located on the right side of the
amplifier and the detector terminal strip is to the left of it. Both terminal strips are factory wired to
the sensor and main circuit board.

Test Points

The test points are on the left side of the amplifier (see Figure 3). The test points produce a 100 mV
to 500 mV output that corresponds to the sample-draw detector’s 4 to 20 mA output. Use the test
points and a voltmeter to measure the amplifier’s output during the start-up and calibration
procedures. The black test point in the upper left corner is the negative (-) test point and the red test
point to the left of the zero and span pots is the positive (+) test point.

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Installation

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

Mounting the Sample-Draw Hydrogen 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?

6.50

1.13

Ø.30x.50(4X)MOUNTING

.78

.40

8.50

Pilot Fail

4.00

Sampl e Drawi ng

s Dete ct or

Ga

35-300 1

8.88

.80

.85

4.50

NOTE: Housing is 4 .3 i nches d eep

Figure 4: 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 4).

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 6 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 6 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 1 for
maximum tubing lengths based on tubing size.

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

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

CAUTION: Avoid lo ops or slumps in the incoming 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 1 for maximum tubing lengths based on
tubing size.

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

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

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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 6 for the arrangement of the fitting components.

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

CAUTION: Avoid lo ops or slumps in the incoming 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 1 for maximum tubing lengths based on
tubing size.

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

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

3. Hand tighten the nut on the exhaust fitting so the ferrules clamp on the tubing. If the tube nut is
removed, see Figure 6 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 1 for maximum tubing lengths based on tubing
size.

Wiring the Sample-Draw Hydrogen 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 three-conductor, shielded cable or three 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

5.

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.

35-3001A-01H Hydro gen Sample-Draw Det ector • 9

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

Not Used on
This Version

S

PWR / SIG

ZE RO

SP AN

OXY LEL/ IR

Red

White

AMP 1

PATS201PATS201

LEL/ IR

+24VDC

AMP 1

OXY

Controller or

Recording

Device

AMP 2

4/20 Signal

-(DCGround)

To

Hydrogen

Se nsor

AMP 2

PATS101PATS101

W

LEL

GBR

Green

Black

Sens or

Current

115m A

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

Figure 5: 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

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

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

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

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

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

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

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

the next section, “Setting the Zero Reading.”

Setting the Zero Reading

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

calibration kit and the zero air calibration cylinder to introduce “fresh air” to the
sensor and verify an accurate zero setting. See “Calibration” on page 18 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).

2. Open the housing door.

3. Set a voltmeter to measure in the millivolt (mV) range.

4. Plug the voltmeter leads into the test points on the amplifier. Plug the positive lead into the red
(+) test point; plug the negative lead into the black (-) test point.

5. Verify a voltmeter reading of 100 mV (± 2 mV).

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6. If necessary, use a small flat-blade screwdriver to adjust the zero potentiometer until the

7. Remove the voltmeter leads from the test points.

8. Close the housing door.

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, monthly, and quarterly 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

voltmeter reading is 100 mV (± 2 mV).

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

3. Verify a display reading of 0 %LEL at the controller or a reading of 100 mV at the amplifier
test points. Investigate significant changes in the display reading.

Monthly Response Test

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

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

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

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

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

Preparing for the response test

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

1. Verify that the display reading at the controller is 0 % LEL.

If the display reading is not 0 % LEL, set the zero reading as described in “Calibration” on
page 18, then continue this procedure.

2. Set a voltmeter to measure in the millivolt (mV) range.

3. Open the housing door, then plug the voltmeter leads into the test points on the amplifier.

Plug the positive lead into the red (+) test point; plug the negative lead into the black (-) test
point.

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4. Use the following formula to determine the correct test points output for the test sample.

Output (mV) = (calibrating sample/fullscale) X 400 + 100

For example, with a test sample of 50 %LEL and a fullscale setting of 100 %LEL, the correct
output is 300 mV.

300 (mV) = (50/100) X 400 +100

Performing the response test

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

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

3. After approximately one minute, verify that the millivolt output at the amplifier stabilizes
within ± 20% of the reading determined above. If the reading is not within ± 20% of the
determined value, calibrate the sample-draw detector as described in “Calibration” on page 18.

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

5. Remove the voltmeter leads from the amplifier test points.

6. Close the housing door.

7. Store the calibration kit in a safe place.

Quarterly Calibration

Calibrate the sample-draw detector as described in “Calibration” on page 18.

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 or a
failure alarm.

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 and/or amplifier 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 and amplifier wiring is correct and secure. “Wiring the Sample­Draw Hydrogen Detector to a Controller” on page 9 describes sensor and amplifier wiring
connections.

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4. Calibrate the sample-draw detector as described in “Calibration” on page 18.

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

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

Slow or No Response/Difficult or Unable to Calibrate

Symptoms

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

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

• The sensor requires 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 Hydrogen Sample-Draw Detector

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

Replacing the Hydrogen 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 two screws that secure the sensor retaining plate, then lift the plate,
connector, and sensor out of the housing.

5. Unplug the connector from the sensor.

6. Verify that you are using the correct replacement sensor (NC-6244A is printed on the sensor),
then plug the sensor into the connector.

7. Place the sensor in the hydrogen sensor cavity, then position the retaining plate on the two
standoffs.

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

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9. Turn on power to the controller and place it into normal operation.

10. Turn on the controller.

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

11. Calibrate the replacement sensor as described in “Calibration” on page 18.

Replacing the Amplifier

1. Turn off the controller.

2. Turn off power to the controller.

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

4. Remove the detector and controller plug-in terminal strips by grasping the sides of the strips
with your fingers. Let the terminal strips hang by their connected wires while you replace the
amplifier.

5. Unscrew the screw in the lower left corner of the amplifier and remove the screw, lock washer,
and flat washer. Be careful not to lose any of these parts.

6. Remove the old amplifier from the main circuit board.

7. Install the new amplifier in the same orientation as the old amplifier. See Figure 1.

8. Reinstall the screw, lock washer, and flat washer you removed in step 5.

9. Install the detector and controller plug-in terminals strips into their sockets on the new
amplifier. If controller leads or detector cable leads were removed from the plug-in terminal
strips during this procedure, refer to Table 2 and Table 3 below.

Table 2:Reconnecting the Amplifier
to the Detector/Amp Terminal Strip

Amplifier Controller

Terminal Strip

PWR/SIG “-” -

PWR/SIG “S” S

PWR/SIG “+” +

Table 3:Reconnecting the LEL

Detector to the Amplifier

Amplifier Detector

Terminal Strip

DETECTOR “R” RED

DETECTOR “W” WHT

Detector/Amp Terminal

Strip on Main PCB

Detector Lead

DETECTOR “G” GREEN

DETECTOR “B” BLK

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NOTE: When the sample-draw detector is first powered up with a new amplifier, the initial

output may be either high or below zero depending on the setting of the zero pot. Be sure
to make arrangements so that this does not cause unwanted alarms.

10. Turn on power to the controller.

11. Turn on the controller and place it into normal operation.

12. Allow the sample-draw detector to warmup for 5 minutes.

13. Calibrate the sample-draw detector as described in “Calibration” on page 18 of this manual.

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:

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:

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1. Use the sensor flow control valve to set the flow to 0.6 SCFH. Turn the valve’s knob

Outside of Case

Fitting Body

Front Ferrule

Back Ferrule

1/4" Tube

1/4" Tube

O-ring

Tube Nut

Inside of Case

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

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

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

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

flowmeter circuit board.

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

3. Turn the sensor flow control valve’s knob counterclockwise to increase the flow until the unit
is out of low flow alarm when the reset switch is pressed and released.

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

If the low flow alarm is set too 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.

Figure 6: Inlet Fitting with Tubing Stub

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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 20 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 20 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 6.

5. Screw the inlet fitting tube nut back onto the fitting body. See “Connecting the Sample Lines to
the Sample-Draw Detector” on page 8 for instructions to install a new piece of tubing into the
fitting.

Calibration Frequency

Calibration

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

If an application is not very demanding, for example detection in a clean, temperature controlled
environment where combustible gases are not normally present and calibration adjustments are
minimal at calibration, then a calibration frequency of every 6 months is adequate.

If an application is very demanding, for example if combustible gases are present often and in
significant concentrations or the environment is not well controlled, then more frequent calibration
than every 3 months may be necessary.

This section describes how to calibrate the hydrogen 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.

3. Open the housing door.

4. Set a voltmeter to measure in the millivolt (mV) range.

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5. Plug the positive lead into the red (+) amplifier test point; plug the negative lead into the black
(-) amplifier test point labeled.

6. Use the following formula to determine the correct test points output for the calibrating
sample.

Output (mV) = (calibrating sample/fullscale) X 400 + 100

For example, with a calibrating sample of 50% LEL and a fullscale setting of 100% LEL, the
correct output is 300 mV.

300 (mV) = (50/100) X 400 +100

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. Verify a voltmeter reading of 100 mV (± 2 mV).

4. If necessary, use a small flat-blade screwdriver to adjust the zero potentiometer until the
voltmeter reading is 100 mV (± 2 mV). If you used a zero air calibration cylinder to set the
zero reading, proceed to step 5. If you verified a fresh air environment, proceed to the next
section, Setting the Response Reading.

5. Disconnect the sample tubing from the inlet line.

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

Setting the Response Reading

1. Screw the regulator into the hydrogen calibration cylinder.

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

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

4. When the reading on the voltmeter stabilizes, verify that the reading matches the response
reading (±2 mV) you determined earlier.

5. If necessary, use the span potentiometer on the amplifier to adjust the reading to match the
correct response reading.

6. Disconnect the sample tubing from the inlet line.

7. Unscrew the regulator from the hydrogen calibration cylinder.

Returning to Normal Operation

1. Wait approximately one minute to allow the hydrogen reading to stabilize.

2. Remove the voltmeter leads from the amplifier test points.

3. Close the housing door.

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

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

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Parts List

Table 4 lists replacement parts and accessories for the sample-draw hydrogen detector.

Table 4: Parts List

Part Number Description

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

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

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

57-1053RK-01 Amplifier (specify target gas when ordering)

61-0155RK Hydrogen sensor, plug-in type, LEL range

71-0307RK Operator’s Manual, 35-3001A-01H Sample-Draw Detector

81-0002RK-01 Calibration cylinder, 50% LEL hydrogen in air, 34 liter steel

81-0002RK-03 Calibration cylinder, 50% LEL hydrogen in air, 103 liter

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

81-0076RK-03 Zero air calibration cylinder, 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)

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