RKI Instruments 35-3001A-05-10, 35-3001A-05-02, 35-3001A-05-03, 35-3001A-05-05 User manual

35-3001A-05-XX

Carbon Dioxide Sample-Draw Detector

Operator’s Manual

Part Number: 71-0340
Revision: B
Released: 6/10/19

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WARNING

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

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

35-3001A-05-XX CO2 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 W ARRAN TI ES
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 PA RTICULAR PURPOSE. IN NO EVENT SHAL L RKI INSTRUM ENTS,
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-05-XX CO2 Sample-Draw Detector

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Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

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

Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

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

35-3001A-05-XX CO2 Sample-Draw Detector

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Overview

This operator’s manual describes the 35-3001A-05-XX carbon dioxide 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 carbon dioxide sample-draw detector. See the controller Operator’s
Manual for information specific to the controller.

Table 1: Specifications

Target Gas Carbon Dioxide (CO

Detection Range 35-3001A-05-02: 0 - 5,000 ppm (parts per million)

35-3001A-05-03: 0 - 5% volume
35-3001A-05-05: 0 - 50% volume
35-3001A-05-10: 0 - 100% 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

Inlet

100 feet 0 feet

50 feet 50 feet

)

2

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

WARNING: When using the 35-3001A-05-XX, you must follow the instructions and warnings in this

manual to assure proper and safe operation of the 35-3001A-05-XX and to minimize the
risk of personal injury. Be sure to maintain and periodically calibrate the 35-3001A-05­XX as described in this manual.

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Inlet

100 feet 100 feet

35-3001A-05-XX CO2 Sample-Draw Dete ctor • 5

Exhaust

Description

Pump

Ox ygen
Sensor
Terminal
Strip

Mounting
Foot, 4X

+

B

O
X
Y
G
E
N

_

W

S

PWR/SIG

Senso r

Current

14 8mA

IR CO2
Flow Block

Pump C onnector

W

LEL

GBR

IR CO2
Sensor PC B

Pilot LED

Fail LED

SensorF low

Control Valve

Pump R eset

Switch

Flowmeter

B

GW

Interconnect
Terminal
Strip

S

+

AMP 1

+

AMP 2

+

WG

OXY

S

R

Hydrophobic

Filter

Particle
Filter

Flowmeter Circuit

Board C onnector

LEL / IR

IR CO2
Sensor
(inside block)

Inlet

Fitting

Exhaust

Fitting

This End
To In let
Fitting

3/4" Conduit H ub

INLET

EXHAUST

IR A mplifier

AMP 2AMP

+

+

W B

Pressu re

Switch

Adjustment

Screw

(behind PCB)

Detector/Amp
Terminal S trip
(Factory
Wired)

LEL / IR

GS R

+

OXY

S

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

Figure 1: Carbon Dioxide Sample-Draw Detector Component Location

6 • 35-3001A-05-XX CO2 Sample-Draw Detector

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External Components

Pump

IR CO2
Sensor

Flowmeter

ParticleFilter

Flowmeter PCB

Exhaust

Pressure Switch

Hydrophobic Filter

Inlet

Restrictor

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 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” 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: Carbon Dioxide Sample-Draw Detector Flow Diagram

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35-3001A-05-XX CO2 Sample-Draw Dete ctor • 7

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

8 • 35-3001A-05-XX CO2 Sample-Draw Detector

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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 20 to adjust this setting.

Pump Reset Switch

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

Hydrophobic Filter

The hydrophobic filter is located toward the bottom left of the main circuit board. The filter prevents
particulates and water in the incoming gas sample from damaging the flow and detection systems. Replace
the filter when it appears dirty, discolored, or clogged.

Pump

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

IR Carbon Dioxide Sensor/IR Carbon Dioxide Sensor PCB

The carbon dioxide sensor is an infrared type plug-in detector. The carbon dioxide sensor is installed in the
IR carbon dioxide flow block and the IR carbon dioxide flow block is mounted to the middle of the main
circuit board. A small circuit board, the IR carbon dioxide sensor PCB, with a 4-wire cable mates to the IR
carbon dioxide sensor and retains it in the flow block. The cable is wired to the main PCB. The IR carbon
dioxide sensor PCB allows you to replace the sensor without disconnecting the wiring.

35-3001A-05-XX CO2 Sample-Draw Dete ctor • 9

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Amplifier

W

LEL

GBR

Test Points

100-500 mV Range

Controller
Terminal Strip

Span Pot

Zero Pot

Factory Set Pots

S

PWR / S IG

Detector

Terminal Strip

The amplifier converts the electrical output from the sensor 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. 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 output during the start-up
and calibration procedures. Turn the adjustment screw clockwise to increase the zero output and
counterclockwise to decrease the zero 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.

10 • 35-3001A-05-XX CO2 Sample-Draw Detector

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Installation

Ø.30x.50(4X)MOUNTING

.78

1.13

.40

Pil o t Fa i l

.85

.80

4.50

NOTE: Housing is4.3 inchesdeep

8.88

4.00

6.50

35-3001

ww w.rkiinstruments.com

Sa mple D r a wing

Gas Detecto r

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 Carbon Dioxide 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

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

• Are the flowmeter and status LEDs visible?

bottom of the housing?

Figure 4: Outline and Mounting Dimensions

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35-3001A-05-XX CO2 Sample-Draw Detector • 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 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 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 6 for the arrangement of the fitting components.

12 • 35-3001A-05-XX CO2 Sample-Draw Detector

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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 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 5 for maximum tubing lengths based on tubing size.

Wiring the Carbon Dioxide 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 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-05-XX CO2 Sample-Draw Detector • 13

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

Not Used on
This Version

ZE RO

S

PWR / SIG

SP AN

OXY LEL/IR

Green

Black

Red

White

PATS201PATS201

AMP 1

AMP 1

OXY

LEL/IR

+24VDC

Controller or

Recording

Dev ice

AMP 2

4/20 S ignal

-(DCGround)

IR CO2

Sensor PCB

AMP 2

PATS101PATS101

Sensor
Current
148m A

IR CO2

Sensor

W

LEL

GBR

Figure 5. Refer to the controller operator’s manual and the controller detector head specification sheet
for the 35-3001A-05-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 • 35-3001A-05-XX CO2 Sample-Draw Detector

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

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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

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.

NOTE: When first powered up, the sample-draw detector will enter about a one minute period when the 4-

the controller.

20 mA output is stabilizing and may be above the controller alarm points or well below zero
momentarily. RKI controllers have a one minute warmup period when the controller does not
display any gas reading or give any alarm indication. The CO

should be stable by the time the controller’s warmup period is over.

transmitter’s 4-20 mA signal

2

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.”

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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. Open the housing door.

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

3. 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.

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

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

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

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

8. If necessary, use a small flat-blade screwdriver to adjust the zero potentiometer until the voltmeter
reading is 100 mV (± 2 mV).

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

10. Remove the voltmeter leads from the test points.

11. 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 sample­draw detector. It includes daily 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 counterclockwise to
increase the flow and clockwise to decrease the flow.

3. Verify a display reading at the controller of the background concentration of CO
concentrations of CO
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.

. Typical background

2

vary from about 300 to 600 ppm (0.03 - 0.06% volume) depending on location.

2

Biannual Calibration

Calibrate the sample-draw detector as described in “Calibration” on page 22.

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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 Carbon Dioxide
Sample-Draw Detector to a Controller” on page 13 describes sensor and amplifier wiring connections.

4. Calibrate the sample-draw detector as described in “Calibration” on page 22.

5. If the fail condition continues, replace the sensor as described in “Replacing the Infrared Carbon
Dioxide Sensor” 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.

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

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

Replacing Components of the Carbon Dioxide Sample-Draw Detector

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

Replacing the Infrared Carbon Dioxide Sensor

1. Turn off the controller.

2. Turn off power to the controller.

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

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

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

5. Unplug the sensor from the IR carbon dioxide sensor PCB.

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

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

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

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 22.

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.

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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 IR Carbon Dioxide Sensor to the Amplifier

Amplifier Detector

Terminal Strip

DETECTOR “R” RED

DETECTOR “W” WHT

DETECTOR “G” GREEN

DETECTOR “B” BLK

Detector/Amp Terminal

Strip on Main PCB

Detector Lead

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 22 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.

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Replacing the Particle Filter

1. Turn off the controller.

2. Turn off power to the controller.

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

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

2. Disconnect the particle filter from the tubing stub.

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

toward the inlet fitting.

4. Reinstall the tubing routed to the sampling area.

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

1. Remove the particle filter from the tubing stub.

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

toward the inlet line.

5. Turn on power to the controller.

6. Turn on the controller.

Adjusting the Low Flow Setting

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

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

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

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

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Removing the Particle Filter’s Tubing Stub, if Necessary

1/4" Tube

Back Ferrule

Front Ferrule

Fitting Body

Outside of Case

1/4" Tube

O-ring

Tube N ut

Inside of Case

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

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 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 12 for instructions to install a new piece of tubing into the fitting.

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Calibration Frequency

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

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

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

Calibration

This section describes how to calibrate the carbon dioxide 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.

2. Open the housing door.

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

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

5. 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 2,000 ppm and a fullscale setting of 5,000 ppm, the correct
output is 260 mV.

260 (mV) = (2000/5000) X 400 +100

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. Screw the regulator into a 100% nitrogen 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. Verify a voltmeter reading of 100 mV (± 2 mV).

5. If necessary, use a small flat-blade screwdriver to adjust the zero potentiometer until the voltmeter
reading is 100 mV (± 2 mV).

6. Disconnect the sample tubing from the inlet line.

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7. 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.

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 carbon dioxide calibration cylinder.

Returning to Normal Operation

1. Wait approximately one minute to allow the carbon dioxide 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 carbon dioxide sample-draw detector.

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)

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

Table 4: Parts List

33-0167RK Particle filter

57-1053RK-10 Amplifier

61-5040RK-02 IR CO

61-5040RK-03 IR CO

61-5040RK-05 IR CO

61-5040RK-10 IR CO

sensor, 0 - 5,000 ppm

2

sensor, 0 - 5% volume

2

sensor, 0 - 50% volume

2

sensor, 0 - 100% volume

2

71-0340 Operator’s Manual, 35-3001A-05-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

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

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

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

calibration cylinders (cylinders with internal threads)

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

(cylinders with external threads)

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