Page 1
35-3010A-09 Sample-Draw
Part Number: 71-0351
Revision: P1
Released: 1/9/15
Detector
www.rkiinstruments.com
Page 2
WARNING
Read and understand this instruction manual before operating
detector . Improper use of the dete ctor 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.
T ypical calibration frequencies for most applications a re between
3 and 6 months, but can be required more often or less often
based on your usage.
35-3010A-09 Sample-Draw Detector
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Product Warranty
RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free fro m defects in
materials, workmanship, and performance for a period of one year fr o m date of shipment
from RKI Instruments, Inc. Any parts found defective withi n tha t 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 ser v ice, and
which must be cleaned, repaired, or replaced on a routine basis. Examples of such items
are:
W arranty 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 , a nd we are not r esponsible for removal or r eplacement costs,
local repair costs, transportation costs, or contingent expenses incurred without our prior
approval.
a) Absorbent cartridges d) Batteries
b) Pump diaphragms and valves e) Filter elements
c) Fuses
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER
WARRANTIES AND REPRESENTATIONS, EXPRESSED OR IMPLIED,
AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF
RKI INSTRUMENTS, INC. INCLUDING BUT NOT LIMITED TO, THE
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS,
INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL
LOSS OR DAMAGE OF ANY KIND CONNECTED WITH THE USE OF
ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR
OPERATE PROPERLY.
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 fo r any accident or dama g e ca u s e d by the operation of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.
35-3010A-09 Sample-Draw Detector
Page 4
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Flow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Detection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting the Sample Lines to the Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wiring the Sample-Draw Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Low Flow Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing Components of the Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjusting the Low Flow Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calibration, IR CH4 Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration, Oxygen Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
35-3010A-09 Sample-Draw Detector
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Overview
This manual describes th e 35 -301 0A-09 sample-draw detector. This manual also describes
how to install, start up, maintain, and calibrate the detector. 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 35-3010A-09.
T a ble 1: Specif icat io ns
Target Gases & Detection Ranges Methane (CH
Oxygen: 0-25% volume
Input Power 24 VDC
Current Draw 240 mA
Output Signals 4-20 mA each channel
Construction (housing) Fiberglass/polyester (NEMA 4X)
Dimensions 15.44 in. H x 12.55 in. W x 8.31 in. D
Weight 14 lbs.
Sampling Method Sample-draw
Sample Flow 1.2 SCFH (nominal)
Response Time 90% in 30 seconds
Accuracy Methane
± 5% of reading or ± 2% of full scale (whichever is greater)
Oxygen
± 0.5% O
): 0 - 100% volume
4
:
:
2
WARNING: When using the 35-3010A-09, you must follow the instructions and
warnings in this manual to assure proper and safe opera tion of the
35-3010A-09 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 35-3010A-09 as described in this
manual.
35-3010A-09 Sample-Draw Dete ctor • 1
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Description
k
r
Hydrophobic
Filter (AcroPak)
This section describes the components of the 35-3010A- 09 sample-draw detector. The sampledraw detector consists of the housing, flow system, and detection system.
CH4
Transmitter
Oxygen TransmitterCharcoal Filter
Main
Circuit
Board
Pump
3/4 Conduit Hub,2X
Exhaust F ittingF or 1/4" O DRigid Tubing
Inlet Fitting F or 1 /4" ODR igid T ubing
Figure 1: Sample Draw Detector Compo n en t Location
Housing
Reset S witch
Amp 1
Preamp
Circuit
Board
Amp 2
H2S Dummy Senso
Oxygen Sensor
CO Dummy Sensor
LEL Dummy Sensor
IR C H 4
Senso r
Flow Bloc
forIR CH4
Flow
Block
The sample-draw detector’s fibe rglass 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.
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. Use the two conduit hubs on the
2 • 35 -3010A -09 Sample-Draw Detector
Page 7
Exhaust
bottom of the housing to make wiring connections.
An aluminum subpanel is mounted to th e interior of the housing. The sample-draw
detector’s internal components are mounted to the subpanel.
Flow System
The sample-draw detector’s flow system consists of the INLET fitting, hydrophobic filter,
charcoal filter, p ump, fl owmeter, bypass valve, status lights, pressure switch, flow blocks,
and EXHAUST fitting (see Figure 1). Figure 2 illustrates how the gas sample moves
through the flow system.
Bypa ss
Valve
Pressure Switch
Flow m eter
Inlet
Flow B loc k
Hydrophobic
Filter
Charcoal
Filter
Pump
CO
Dummy
Plug
LEL
Dummy
Plug
H2S
Dummy
Plug
Oxygen
IR CH4
Figure 2: Sample Draw Detector Fl ow Diagram
INLET Fitt i n g
The INLET fitting on the bottom of the housing allows the gas sample to enter the sampledraw detector. The INLET fitting accepts 1/4 in. rigid tubing. See “Installation” on
page 10 for instructions to conn ect tubing to the INLET fitting.
Hydrophobic Filter
The hydrophobic filter is to the left of the main circuit board. It is held in place by a metal
clip. It prevents water and other liquids from contaminating the flow system. Replace the
filter when it appears dirty, discolored, or clogged. If a liquid other than water is drawn
into the filter, repl ace the filter as soon as possible.
35-3010A-09 Sample-Draw Dete ctor • 3
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Charcoal Filter
The charcoal filter is located above the CH
The charcoal filter is placed after the H
transmitter. It is held in place by a metal clip.
4
S sensor (if one is installed) and before the CO
2
sensor (if one is installed) in the flow system. It scrubs out interfering gases which may
cause the CO sen sor t o r espo nd, su ch as H
S or certain hydrocarbons. It is included in this
2
version of the sample draw detector in case a CO sensor is added in the field. If a CO
sensor is added in the field, a new charcoal filter should also be installed.
Pump
The pump is located to the left of the main circuit board near the bottom left of the
sample-draw detector. The pump pulls the gas sample into the sample-draw detector. The
pump operates on 24 VAC, which is generated from the 24 VDC supplie d to the sample
draw detector.
Flowmeter
The flowmeter is attached to the main circuit board near the top left corner (see Figure 1).
A ball in the flowmeter column indicates the flow rate of the sample-draw detector. The
flowmeter measures the flow in the range 0.2 to 2.0 SCFH (Standard Cubic Feet per Hour).
Although the sample-draw detector will operate down to a flow of 0.6 SCFH, the
optimum flow rate is 1.2 SCFH.
Bypass Valve
The bypass valve is to the left of the flowmeter. The bypass valve adjusts the flow rate to
the sensor. Use a flat-blade screwdriver to adjust the bypass valve.
NOTE: The bypass valve allows fine adjustments of the flow rate. For a wider range of
adjustment, use the flow adjust potentiometer (see Figure 1).
Status Lights
Two status lights are above the flowmeter.
Pilot Light
The green Pilot light is on when the sample-draw detector is receiving power.
Fail Light
The red Fail light is on when the sample flow rate is below the low flow level.
NOTE: The factory set low flow level is 0.6 SCFH (±0.2). See “Adj usting the Low Flow
Setting” on page 19 for instructions to adjust this setting.
Pressure Switch
The pressure switch is mounted to the opposite side of the main 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
relay to interrupt the signal in the 4-20 mA line for the CO and H
S channels (if installed).
2
This causes a downscale reading at the monitor on these channels. The low flow level is
factory-set at 0.6 SCFH (±0.2 SCFH).
NOTE: There is no low flow indication for the CH4 or oxygen channels.
4 • 35 -3010A -09 Sample-Draw Detector
Page 9
Flow Blocks
Both flow blocks are located in the lower right corner of the sample-draw detector. The
oxygen sensor is installed in the larger flow block. The smaller flow block houses the IR
CH
sensor. The flow blocks route the sampled air to each sensor.
4
EXHAUST Fitting
The EXHAUST fitting on the bottom of the housin g allows the gas sample to exit the
sample-draw detector. The EXHAUST fitting accepts 1/4 in. rigid tubing. See
“Installation” on page 10 to connect tubing to the EXHAUST fitting .
Detection System
The detection system consists of the gas sensors, CH4 and oxygen transmitters, preamp
circuit board, and the main circuit board.
IR CH
Sensor
4
The infrared CH4 sensor is installed in the smaller flow block in the lower right corner. A
small circuit board with a cable mates to it and retains it in the block. The cable is wired to
the main PCB.
Oxygen Sensor
The oxygen sensor is installed in the lower right corner of the larger flow block. It consists
of a cylindrical body which houses the detection elements and a cable which terminates in
a round 7-pin male connector. The sensor connector mates to a 7-position socket that is
wired to the main PCB.
Carbon Monoxide Sensor
The CO sensor position in the flow block is occupied by a plastic dummy plug in the
35-3010A-09.
Hydrogen Sulfide Gas Sensor
The H
S sensor position in the flow block is occupied by a plastic dummy plug in the
2
35-3010A-09.
35-3010A-09 Sample-Draw Dete ctor • 5
Page 10
CH4 Transmitter
The CH4 transmitter is mounted to the left of the oxygen transmitter and above the main
circuit board. It consists of the span pot, zero pot, one internally wired terminal strip, and
the test points.
Interconnect
Termin al S tr ip
P/N 57-1 050RK
REV. 0
GND
24V
TP+
4-20
POWER/SIG
RED
WHT
INSTRUMENTS
GRN
SPAN ZERO
TP-
SENSOR
BLK
Test Point TP+
Test Point T P-
Span Pot
Zero Pot
Figure 3: CH
Span/Zero Pots
The span and zero pots are located at the bottom edge of the transm itter and are used for
calibration. Use the span pot to make adjustments to gas response readings and the zero
pot to make adjustments to the zero reading
Transmitter Interconnect Terminal Strip
The transmitter interconnect terminal strip is the seven-point terminal strip near the right
edge of the transmitter. The transmitter is factory wired to the sensor and main circuit
board.
T est Points
The test points are located on the left side of the transmitter and are labeled TP+ and TP-.
A 100 mV - 500 mV outpu t is available at these test points for use during calibration.
Transmitter Component Location
4
6 • 35 -3010A -09 Sample-Draw Detector
Page 11
Oxygen Transmitter
The oxygen transmitter is mounted to the right of the CH
circuit board. The amplifier includes the amplifier type selector, two internally wired
terminal strips, span pot, zero pot, and test points.
Test Point TP-
Zero Pot
Span Pot
Transmitter
Type S elector,
Set To OXY
TP -
ZERO
SPAN
OXY
TOXIC
BATT
TOXIC
RD
+
4/20
BK W
FB
OXY
24V
transmitter and above the main
4
Sensor Terminal
Strip
+
TP +
Test Point TP+
G
Interconnect
Terminal Strip
Figure 4: Oxgyen Transmitter Component Location
Transmitter Type Selector
The transmitter type selector is near the bottom left corner of the amplifier. It is to the left
of the detector terminal strip and below the span pot.
The transmitter included with the sample-draw detector is designed for use with RKI’s
oxygen and toxic gas sensors. The transmitter type selector determines for which sensor
the amplifier is intended. For oxygen transmitters, a jumper blo c k is installed over the
OXY selector.
Detector Terminal Strip
The detector terminal strip is the four-point terminal strip near the bottom edge of the
transmitter. It is factory wired to the transmitter.
Interconnect Terminal Strip
The interconnect terminal strip is the four-point terminal strip near the top edge of the
transmitter. It is factory wired to the main circuit board.
Span/Zero Pots
The span and zero pots are located on the left side of the transmitter and are used for
calibration. Use the span pot to make adjustments to gas response readings and the zero
pot to make adjustments to the zero reading.
T est Points
The test points are located on the top of the transmitter on either side of the transmitter
interconnect terminal strip. They are labeled TP+ and TP-. A 100 mV - 500 mV output is
available a t these test p o ints for use during cali bration.
35-3010A-09 Sample-Draw Dete ctor • 7
Page 12
Preamp Circuit Board
Reset
Switch
Pilot LED
The preamp circuit is used to connect the CO and H
S sensors to the main circuit board
2
and to secure the sensors in the flow block. Two cables mate to the main circuit board: the
one on the left is for the CO sensor signal and the one on the right is for the H
signal. Since the CO and H
the CO and H
S sensor signal cables carry no signal in this version of the 35-3010RK.
2
S sensors are replaced with a dummy plug in the 3 5-3 01 0A-09
2
S sensor
2
Main Circuit Board
Pump Te r mi n al Stip
Fai l LED
Flowmeter
Flow Adjust Pot
Low Flow Adjust
Relay
Pressure Switch
Test Point CAL - 1
Tes t Po int CAL + 1
Tes t Po int CAL - 2
Test Point CAL + 2
Interconnect Terminal
Strip
AC Terminal
Strip Not Used
Zero Span Zero
Amp 1
(CO)
Sensor/Transmitter
Terminal Strip
Span
Amp 2
(H2S)
Figure 5: Main Circuit Board
The main circuit board includes the interconnect terminal strip, sensor/transmitter
terminal strip, amp 1 circuit, amp 2 circuit, pump terminal strip, relay, and reset switch
(see Figure 5).
NOTE: The flowmeter and status lights are mounted to the main circuit board but are
considered part of the flow system.
Interconnect Terminal Strip
The interconnect terminal strip is the sixteen-point terminal strip near the bottom edge of
the main circuit board. Use the interconnect terminal strip to connect the sample-draw
detector to power and an external device.
8 • 35 -3010A -09 Sample-Draw Detector
Page 13
Sensor/Transmitter Terminal Strip
The sensor/transmitter terminal strip is the sixteen-point terminal strip near the right
edge of the circuit board. Use the transmitter terminal strip to connect sensors or
transmitters to the main circuit board.
NOTE: The sensors and transmitters are factory wired to the sensor/transmitter
terminal strip. See “Wiring the Sample-Draw Detector” on page 11 for all wiring
procedures related to the sample-draw detector.
Amp 1 and Amp 2 Circuits
These circuits are located to the left of the sensor/transmitter terminal strip. They each
include test points, a zero pot, and a span pot. Amp 1 is on the left and is for the CO
channel. Amp 2 is on the right and is for the H
S channel. Since there is no CO or H2S
2
channel in the 35-3010A-09, neit her amp is used.
The zero and span po ts are used during calibration. Use th e span pot t o mak e adj ustment s
to gas response readings and the zero pot to make adjustments to the zero reading.
The test points are labeled CAL-1 and CAL+1 for the CO channel and CAL-2 and CAL+2
for the H
Pump Terminal Strip
S channel. No output is available at any of the test points.
2
The pump terminal strip is the four-point terminal in the top left corner of the circuit
board. Use the pump terminal strip to connect the pump and pressure switch to the main
circuit board.
NOTE: The pump and pressure switch are factory-wired to the circuit board. See
“Installation” on page 10 for all wiring procedures related to the sample-draw
detector.
Relay
The relay is approximately in the middle of the circuit board. The relay is a four pole,
double-throw (4PDT) relay and is rated for 2 amps at 25 VDC (resistive). If the pressure
switch senses a low flow condition, the relay interrupts the 4-20 mA signal from the CO
and H
device. The 35-3010A-09 does not have a CO or H
S channels which will cause a downscale reading at the controller or recording
2
S sensor installed so the relay has no
2
effect in this version of the 35-3010RK.
NOTE: There is no flow fail indication for the CH4 and oxygen channels on the
35-3010A-09 Sample Draw Adapter.
Reset Switch
A small reset button is located in the upper left corner of the main PCB. When a low flow
condition occurs, the pump will be shut off. To reset the low flow condition and sta r t the
pump again, press and hold the reset sw itch for about 2 seconds, then release.
35-3010A-09 Sample-Draw Dete ctor • 9
Page 14
Installation
This section describes procedures to mount the sample-draw gas detector in the
monitoring environment and wire the sample-draw detector to power and an external
device.
Mounting the Sample-Draw Detector
1. Sele ct the mounting site. Consider the following when you select the mounting site.
• Is there enough room to open the housing door and make wiring connections at
the bottom of the housing and tubing connections at the right of the housing?
• Make sure there is sufficient room to perform start-up, maintenance, and
calibration procedures.
12.55
10.00
Ø .31 x .50 slot, 4X
8.31
.18
14.94
14.55
15.44
3/4" Conduit Hub, 2X
Tube Fitting for 1/4" OD
Door Latch
Tube, 2X
Figure 6: Outline and Mounting Dimensions
7. 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.
8. S lightly loosen the screw that secures one of the mounting feet to the housing, then
rotate the mounting foot 180 degrees (see Figure 6).
10 • 35-3010A-09 Sample-Draw Detector
Page 15
9. Tighten the screw that secures the mounting foot to the housing.
10. Repeat steps 8 and 9 for the remaining three mounting feet.
11. Position the sample-draw housing on a vertical surface at eye level (4 1/2 to 5 feet
from the floor).
12. Insert 1/4 in. or 5/16 in. 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
1. Attach 1/4 in. O.D. rigid polypropylene or rigid Teflon sample tubing to the INLET
fitting.
CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate
insert to seal the connection between the tubing and th e INLET fitting.
2. Place the opposite end of the tubing at the sampling area.
CAUTION: Avoid loops or slumps in the incoming sample line. To reduce response time, keep the
incoming sample line as short as possibl e.
3. Atta ch rigid sample tubing to the EXHAUST fitting.
4. Route the opposite end of the tubing to an open area or to a downstream area of the
sampled gas stream where the sample can safely disperse.
WARNING: This instrument samples potentially high levels of methane. Be sure to
route the instrument’s exhaust to a location where it can safely disperse.
Wiring the Sample-Draw Detector
WARNING: Always verify that the power source is OFF before you make wiri ng
connections.
1. Turn off the controller.
2. Turn off or unplug incoming power to the controller.
3. U nlatch and open the housing door of the sample- draw detector.
4. Guide a six-conductor 18 gauge, shielded cable or six 18 gauge wires in conduit
through one of the conduit hubs at the bottom of the sample-draw housin g. If
necessary, use both hubs to bring the wires in making sure that all the wires for a
particular channel go through the same hub.
5. Connect the cable to the sample-draw detector’s interconnect terminal strip as shown
in Figure 7.
6. Close and latch the hous ing door of the sample-draw detector.
CAUTION: Leave the cable shield drain wire insulated and disconnected at the sample-draw
detector. You will connect the op posite end of the dra i n wire at the controller.
7. Route the cable or wires in conduit leading from the sample-draw detector to the
controller.
35-3010A-09 Sample-Draw Detector • 11
Page 16
8. Connect the drain wire to an available chassis ground at the controller end. RKI
controllers typically have a ground stud that can be used to ground the cable’s drain
wire.
Sample Draw Housing
Main CircuitBoard
Reset Switch
Oxygen
(Controller
Transmitter
Termina ls)
24 VDC
4-20 (Feedback)
Figure 7: Extern al (Field) Wiring, Sa mple-Draw Dete ctor
Interconnect Terminal Strip
-
+
4/20 Fee dback
+
24 VDC
-
LEL (Controller
Transmitt er
Termina l s)
12 • 35-3010A-09 Sample-Draw Detector
Page 17
Pump
Factory
Wired
IR CH4 Sensor
Connector
Black
G reen
White
Red
P/N 57-105 0RK
REV.0
TP+
SPAN Z ERO
TP-
GND
24 V
4-20
POWER/SIG
RED
WHT
INSTRUMENTS
GRN
SENSOR
BLK
Pressure Switch
Factory W i red
ZERO
SPAN
TP -
OXY
TOX IC
TP +
OXY
TOX IC
G
BK WRD
+
+
FB
24V4/20
BATT
Green
White
IR CH4
Detector
CO and H2SSensors Plug Into
FarS ide of P r eamp
Circuit Board
Figure 8: Internal (Factory) Wiring, Sample-Draw Det ector
CO
(Not
Use d)
H2S
(Not
Used)
Oxygen Sensor
35-3010A-09 Sample-Draw Detector • 13
Page 18
Start Up
This section describes procedures to start up the sample-draw detector and place t he
sample-draw detector into normal operation.
Introducing Incoming Power
1. Complete the installation procedures described earlier in this manual.
2. Verify that the power wiring to the controller is correct and secure. See the controller
operator’s ma nual.
3. Turn on or plug in the incoming power at the controller, then turn on the controller.
4. Verify that the Pilot light is on at the sample draw detector.
5. Verify that the controller is on and operating properly.
6. Verify that the flowmeter indicates a flow rate of approximately 1.2 SCFH. If
necessary, use the bypass valve or flow adjust potentiom eter to adjust the flow rate.
NOTE: The following step tests for leaks in the sample lin e. T his test may cause a low
flow condition at the sample-draw detector.
7. Verify that the incoming sample line is not leaking. To test th e samp le line, 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, press the pump reset switch, and verify the
flowmeter returns to a normal flow rate.
Setting the Zero Reading
CAUTION: If you suspect the presence of combustible gas or an abnormal oxygen condition (not
20.9%) in the monitoring environment, use the calibration kit and the zero air
calibration cylinder to introduce “fresh air” to the sample draw adapter and verify an
accurate zero setting.
1. Verify that the sample-draw detector is sampling a fresh air environment
(environment known to be free of combust i bl e ga s, and of normal oxyge n co nt ent,
20.9%).
2. Open the housing door.
3. S et a vol tmeter to measure in the millivolt (mV) range.
4. Plu g the voltmeter leads into the transmitter test points.
•For the IR CH
transmitter. Plug the positive lead into the test point labeled TP+; plug the
negative lead into the test point labeled TP-.
• For the oxygen channel, plug the voltmeter into the test points on the oxygen
transmitter. Plug the positive lead into the test point labeled TP+; plug the
negative lead into the test point labeled TP-.
channel, plug the voltmeter leads into the test points on the CH4
4
5. Verify a voltmeter reading of 100 mV (± 2 mV) at the CH
6. If ne ce ssary, use a small flat-blade screwdriver to adjust the CH
pot until the voltmeter reading is 100 mV (± 2 mV).
7. Verify a voltmeter reading of 434 mV (± 2 mV) at the oxygen transmitter.
14 • 35-3010A-09 Sample-Draw Detector
transmitter.
4
transmitter’s zero
4
Page 19
Operation
8. If necessary, use a small fl at-blade screwdriver to adju s t the oxygen transmitter’s zero
pot until the voltmeter reading is 434 mV (± 2 mV).
9. Close the housing door.
Normal Operation
During normal operation, the Pilot LED will be on and the flowmeter will indicate about
1.2 SCFH. The current gas readings will be indicated at the controller. See the controller’s
operator’s manual for a description of the reading indications.
Low Flow Alarm
If the flowrate falls below 0.6 SCFH (±0.2 SCFH), then the sample draw detector will
initiate a low flow alarm. In a low flow alarm the Fail LED will turn on and the pump will
shut off. If a low flow alarm occurs, press the pump reset switch for about 2 seconds to
restart the pump and turn off the Fail LED. If the condition continues, find the cause of the
reduced flow, correct it, and restart the pump with the pump reset s witch . A flow
reduction can be caused by a flow blockage, a leak in the flow system, a m alfunctioning
pressure switch, or a malfunctioning pump.
NOTE: There is no flow fail indication for the CH4 and oxygen channels on the
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, and adjust the low flow
setting.
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
1. Verify that the pilot light is on.
2. Verify that the flowmeter indicates a flow rate of approximately 1.2 SCFH.
3. Verify a reading of 0% volume for the IR CH
35-3010A-09.
If necessary use the bypass valve or flow ad just potentiometer to adjust the flow rate
to 1.2 SCFH.
channel (100 mV at the CH4 transmitter
4
test points) and 20.9% for the oxygen channel (434 mV at the oxygen transmitter test
points). Investigate significant changes in the reading.
35-3010A-09 Sample-Draw Detector • 15
Page 20
Monthly
This pr oc edure describes a test to verify that the sample-draw detector responds properly
to the target gases.
Preparing for the response test
CAUTION: This procedure may cause alarms at the controller. Take appropriate action to avoid
this, such as entering the calibration mode at the controller.
1. Verify that the controller is reading 0% volume for the IR CH
channel and 20.9% for
4
the oxygen channel.
If the reading is not 0% volume on the IR CH
channel or 20.9% on the oxygen
4
channel, set the zero r e ading a s described i n “Start Up” on page 14, then continue this
procedure.
2. A ssemble the calibration kit as described in the Calibratio n section of this manual.
Performing the response test
NOTE: This procedure describes the RKI calibration kit that includes a demand flow
regulator.
1. Screw the regulator into the methane calibration cylinder.
2. Connect the cali brat io n tu bi ng fr om the r e gula tor to the inlet line at or near the INLET
fitting. Gas will begin to flow.
3. After approximately one minute, verify that the reading for the IR CH
channel at the
4
controller stabilizes within ± 20% of the concentration of the test sa mple. If the
reading is not within ± 20% of the test sample, calibrate the sample-draw detecto r as
described in “Calibration, IR CH
Detector” on page 20.
4
4. Remove the calibration tubing from the inlet line.
5. Store the calibration kit in a safe place.
6. E x hale into the sample-draw detector’s inlet line.
7. S top exhaling into the inlet line, then verify that the oxygen reading at th e controller
decreased.
8. If the reading did not decrease, calibrate the sample-draw detector as described in
“Calibration, Oxygen Detector” on page 21.
9. Reconnect the inlet line.
Quarterly
Calibrate the sample-draw detector as described in “Calibration, IR CH
page 20 and “Ca libration, Oxygen Detector” on page 21.
Troubleshooting
The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the sample-draw gas detector.
NOTE: This troubleshooting guide describes sample-draw detector problems only. See
the instruction manual for the controller if it exhibits any problems.
16 • 35-3010A-09 Sample-Draw Detector
Detector” on
4
Page 21
Fail Condition
Symptoms
• The sample-draw detector’s Fail light is on.
• The controller is operating properly but indicates a reading well below zero on one or
more channels.
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 malfunction ing.
• The sensor or transmitter wiring is disconnected or misco nnected.
Recommended Action
1. At the sample-draw detector, set the correct flow rate with the bypass valve or flow
adjust potentiometer.
2. If you cannot set the correct flow rate, check the sample lines for obstructions or kinks.
3. Verify that the sensor and transmitter wiring are correct and secure. “Wiring the
Sample-Draw Detector” on page 11 describes detector wiring connections.
4. Ca librate the problem channel or channels as described in the Calibrati on section.
5. If the fail condition continues, replace the sensor from the problem channel or
channels as described later in this section.
6. If the fail condition continues, contact RKI Instruments, Inc. for further instruction.
Slow or No Response/Difficult or Unable to Calibrate
Symptoms
• One or more of the sensors respond slowly or does not respond during the monthly
response test.
• Unable to accurately set the zero or response reading on one or more of the channels
during the calibration procedure.
• One or more of the sensors requires frequent calibration.
NOTE: Under “normal” circumstances, the sample- draw de tector requires calibration
once a quarter. Some applications may require a more frequent calibration
schedule.
Probable Causes
• The calibration cylinder is low, out-dated, or defective.
• The sample-draw detector’s flow rate is too low because of an obstructed sample line,
failed pump, etc.
• The sample-draw detector is malfunction ing.
Recommended Action
1. V erify that the calibration cylinder contains an adequate suppl y of a fresh test sample.
2. If necessary, set the correct flow rate with the bypass valve or flow adjust
potentiometer.
3. If you ca nnot set the correct flow rate, check the sample line for obstructions or kinks.
35-3010A-09 Sample-Draw Detector • 17
Page 22
4. If the calibration/response difficulties continue, replace the sensor as described later
in this section.
5. If t he calibration/response difficulties continue, contact RKI Instruments, Inc. for
further instruction.
Replacing Components of the Sample-Draw Detector
This section includes procedures to replace the sensors, the hydrop hobic filter, and the
charcoal filter.
Replacing the IR CH
Sensor
4
1. Turn off or unplug incoming power.
2. Unscrew the four screws that hold the circuit bo ard on the flow block.
3. Pul l the circuit board off the flow block.
4. Unplug the in frared detector from the circuit board.
5. Plug the new detector into the circuit board.
6. Rei nstall the circuit board to the flow block.
7. Turn on or plug in power.
8. Ca librate the replacement sensor as described in “Calibration, IR CH
Detector” on
4
page 20.
Replacing the Oxygen Sensor
1. Tu rn off incoming power.
2. Open the housing door of the sample-draw detector.
3. Unscrew and remove the two screws that secure the retaining plate, then lift the plate,
connector, and sensor out of the housing.
4. Unplu g the connector from the socket that leads from the sensor.
5. Plug the socket of the replacement sensor into the connector.
6. Place the sensor in the oxygen sensor cavity, then position the retaining plate on the
two standoffs.
7. Secure the retaining plate to the standoffs with the two screws you removed in step 3.
8. Turn on incoming power.
9. Calibrate the replacement sensor as described in “Calibration, Oxygen Detector” on
page 21.
Replacing the Hydrophobic Filter
1. Turn off or unplug pow er to the co ntroller.
2. Locate the hydrophobic filter. It is just to the left of the main circuit board.
3. Gra sp the hydrophobic filter and pull it out of its metal clamp.
4. Remove the rubber seals from each end of the hydrophobic filter and remove the
filter.
5. Place the new hydrophobic filter in the same orientation as the one that was removed.
6. Place the new hydrophobic filter back into the metal clamp.
18 • 35-3010A-09 Sample-Draw Detector
Page 23
Replacing the Charcoal Filter
NOTE: The charcoal filter does not normally need to be repl aced in the 35-3010A-09
because it does not include a CO sensor.
1. Turn off or unplug pow er to the co ntroller.
2. Locate the charcoal filter. It is located along the upper edge of the detector housing.
3. Grasp the charcoal filter and pull it out of its metal clamp.
4. Remove the rubber seals from each end of the charcoal filter and remove the filter.
5. Place the new charcoal filter in the same orientation as the one that was removed.
6. Place the new charcoal filter back into the metal clamp.
Adjusting the Low Flow Setting
The factory-set low flow setting is 0.6 SCFH (±0.2). To adjust the low flow setting:
1. Use the flow adj ust potentiometer (VR1) to set the flow to 0.6 SCFH.
If the sample-draw detector goes into low flow alarm before you can adjust the flow
down to 0.6 SCFH, adjust the low flow potentiometer 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.
2. Slowly turn the low flow potentiometer counterclockwise just un til the sample-draw
detector goes into low flow alarm.
NOTE: The low flow potentiometer is accessible through a circular cutout in the main
circuit board. The cutout is labeled PS1.
3. Verify that the low flow alarm is 0.6 SCFH (±0.2). Repeat steps 1 and 2 if necessary.
4. Use the flow adjust potentiometer (VR1) to set the flow to 1.2 SCFH.
5. M ake sure the sample-draw detector’s Fail light is off.
Calibration Frequency
Although there is no particular calibration frequency that is correct for all applications, a
calibration frequency of every 3 months is adequate for most sample draw detector
applications. Unless experience in a particular application dictates otherwise, RKI
Instruments, Inc. recommends a calibration frequency of every 3 months for the oxygen
sensor and every 6 months for the IR CH
If an application is not very demanding, for example detection in a clean, temperature
controlled environment, and calibration adjustments a re minima l at calibration, then a
calibration fre quency of e very 6 month s for t he ox ygen s ensor and eve ry 12 month s for t he
IR CH
sensor is adequate for the sample draw detector.
4
sensor in the sample draw dete ctor.
4
If the application is very demanding, for example if the environment is not well
controlled, then more frequent calibration than every 3 months for the oxygen sensor and
every 6 months for the IR CH
sensor may be necess ary for the sample draw detector.
4
35-3010A-09 Sample-Draw Detector • 19
Page 24
Calibration, IR CH4 Detector
This section describes how to calibrate the IR CH4 sensor in the sample draw detector. It
includes procedures to prepare for calibration, set the zero reading, set the response
reading, and return to normal operation.
NOTE: This procedure describes calibration using a demand flow regulator, a zero air
calibration cylinder, and a methane calibration cylinder.
Prepari ng for Ca libration
CAUTION: This procedure may cause alarms at the controller. Take appropriate action to avoid
this, such as entering the calibration mode at the controller.
1. Open the housing door.
2. S et a vol tmeter to measure in the millivolt (mV) range.
3. Plu g the voltmeter into the test points on the CH
transmitter. Plug the positive lead
4
into the test point labeled TP+; plug the ne gative lead into the test point labeled TP-.
4. Use the foll owing 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 %volume methane and a fullscale setti ng
of 100 %volume, the correct output for the CH
test points is 300 mV.
4
300 (mV) = (50/100) X 400 +100
Setting the Zero Reading
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.
1. S c rew the regulator into the ze ro air calibration cylinder.
2. Connect th e calibration kit sample tubing to the regulator.
3. Connect the sample tubing from the regulator to the inlet line at or near the INLET
fitting.
4. Allow the gas to flow for one minute.
5. Verify a voltmeter reading of 100 mV ± 2 mV at the CH
Preparing for Calibration section above.
6. If necessary, use a small flat-bla de screwdriver to adjust the zero pot for the IR CH
channel until the voltmeter reading is 100 mV ± 2 mV.
test points as described in the
4
4
7. Disconnect the sample tubing from the inlet line.
8. Unscrew the regulator from the zero air calibration cylinder. Leave the sample tubing
connected to the regulator.
20 • 35-3010A-09 Sample-Draw Detector
Page 25
Setting the Response Reading
1. Screw the regulator into the methane calibration cylinder.
2. Connect th e sample tubing from the regulator to the inlet line at or near the sampledraw detector’s INLET fitting.
3. A llow the calibration gas to flow for one minute.
4. Check the mV o utput o n th e CH
matches the response reading (±2 mV) you determined earlier.
5. If necessary, use the span pot on the CH
the correct response reading.
6. Disconnect the sample tubing from the sample-draw detector’s inlet line.
7. Unscrew the regulator from the calibration cylinder.
NOTE: For convenience, leave the regulator connected to the sample tubing.
transmitter test points and verify that the reading
4
transmitter to adjust the reading to match
4
Returning to Normal Operation
1. Remove the v oltm eter leads from the test points.
2. Reconnect the incoming sample line.
3. Wait 1 to 2 minutes to allow the calibration gas to be drawn out and the reading to
stabilize.
4. Close the housing door.
5. Store the components of the calibration kit in a safe and convenient place.
Calibration, Oxygen Detector
This secti on de scri be s h ow t o c ali br ate the ox ygen detector in the sample-draw detector . It
includes procedures to prepare for calibration, set the zero reading, set the fresh air
reading, and return to normal operation.
NOTE: This procedure describes calibration using a demand flow regulator, a zero air
calibration cylinder, and a 100% nitrogen calibration cylinder to set the zero
reading.
Prepari ng for Ca libration
CAUTION: This procedure may cause alarms at the controller. Take appropriate action to avoid
this, such as entering the calibration mode at the controller.
1. Open the housing door.
2. S et a vol tmeter to measure in the millivolt (mV) range.
3. Plu g the voltmeter into the test points on the oxygen transmitter. Plug the positive
lead into the test point labeled TP+; plug the negative lead into the test point labeled
TP-.
35-3010A-09 Sample-Draw Detector • 21
Page 26
Setting the Zero Reading
1. Screw the regulator into the 100% nitrogen calibration cylinder.
2. Connect th e calibration kit sample tubing to the regulator.
3. Connect th e sample tubing from the regulator to the inlet line at or near the sampledraw detector’s INLET fitting.
4. Allo w the sample-draw detector to respond to the calibrating sample for
approximately 1 minute.
5. After one minute, check the mV output on the oxygen transmitter test points and
verify a reading of 100 mV (±2 mV).
6. If necessary, use the span pot on the transmitter to adjust the reading to 100 mV
(± 2 mV)
7. Disconnect the sample tubing from the inlet line.
8. Unscrew the regulator from the 100% nitrogen calibration cylinde r.
9. For convenience, leave the regulator attached to the sample tubing.
Setting the Fresh Air Reading
CAUTION: This procedure may cause alarms at the controller. Take appropriate action to avoid
this, such as entering the calibration mode at the controller.
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.
1. S c rew the regulator into the ze ro air calibration cylinder.
2. Connect th e calibration kit sample tubing to the regulator.
3. Connect the sample tubing from the regulator to the inlet line at or near the INLET
fitting.
4. Allow the gas to flow for one minute.
5. Verify a voltmeter reading of 434 mV ± 2 mV at the test points as described in the
Preparing for Calibration section above.
6. If necessary, use a small flat-blade screwdriver to adjust the zero pot until the
voltmeter reading is 434 mV ± 2 mV.
7. Disconnect the sample tubing from the inlet line.
8. Unscrew the regulator from the zero air calibration cylinder. Leave the sample tubing
connected to the regulator.
Returning to Normal Operation
1. Reconnect the incoming sample line.
2. Wait 1 to 2 minutes to allow the calibration gas to be drawn out and the reading to
stabilize.
3. Close the housing door.
4. Store the components of the calibration kit in a safe and convenient place.
22 • 35-3010A-09 Sample-Draw Detector
Page 27
Parts List
Table 4 lists replacement parts and accessories for the sample-draw gas detector.
Table 2: Parts List
Part Number Description
06-1248RK Sample tubing, 3/16 in. x 5/16 in., specify length (for calibration kit)
30-0610RK Pump
33-0171RK Hydrophobic filter (AcroPak)
33-6095RK Charcoal filter, CF-188
61-5041RK-CH4 Infrared methane sensor, plug-in type, %vol range
65-0601RK Oxygen sensor
81-0013RK-01 Calibration cylinder, 50% vol methane in nitrogen, 34 liter steel
81-0013RK-05 Calibration cylinder, 50% vol methane in nitrogen, 58 liter steel
81-0076RK-01 Zero air calibration cylinder, 34 liter
81-0078RK-01 Calibration cylinder, 100% nitrogen, 34 liter
81-0078RK-03 Calibration cylinder, 100% nitrogen, 103 liter
81-1054RK Regulator, demand flow, for 58- and 103-liter steel cylinders
81-1055RK Regulator, demand flow, for 17- and 34-liter steel cylinders
35-3010A-09 Sample-Draw Detector • 23
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