RKI Instruments 35-3010RK-07 User Manual
35-3010RK-07 Sample-Draw
Part Number: 71-0214RK
Revision: B
Released: 9/10/12
Detector
www.rkiinstruments.com
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.
35-3010RK-07 Sample-Draw Detector
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.
35-3010RK-07 Sample-Draw Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Flow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Detection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting the Sample Lines to the Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wiring the Sample-Draw Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low Flow Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacing Components of the Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjusting the Low Flow Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Calibration, H2S Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calibration, IR CH4 Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration, Oxygen Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
35-3010RK-07 Sample-Draw Detector
Overview
This manual describes the 35-3010RK-07 sample draw detector. This manual also
describes how to install, start up, maintain, and calib rate the sample draw detector wh en
it is used with a gas monitoring controller. A parts list at the end of this manual lists
replacement parts and accessories for the detector.
Specifications
Table 1 lists specifications for the 35-3010RK-07.
Table 1: Specifications
Target Gases & Detection Ranges Methane (CH
): 0 - 100% LEL
4
Oxygen: 0-25% volume
Hydrogen Sulfide (H
S): 0 - 100 ppm
2
Input Power 24 VDC
Current Draw 200 mA
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 (CH
):
4
± 5% of reading or ± 2% full scale (whichever is greater)
Oxygen
± 0.5% O
:
2
Hydrogen Sulfide (H2S):
± 5% of reading or ± 2 ppm H
S (whichever is greater)
2
WARNING: When using the 35-3010RK-07, you must follow the instructions and
warnings in this manual to assure proper and safe opera tion of the
35-3010RK-07 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 35-3010RK-07 as described in this
manual.
35-3010RK-07 Sample-Draw Detector • 1
Description
Amp 2
IR CH4
Sensor
Flow Block
for IR CH4
Preamp
Circuit Board
Amp 1
Charcoal Filter
Hydrophobic Filter
(AcroPak)
Flow Block for
Oxygen and H2S
Pump
Oxygen Sensor
H2S Sensor
Dummy Plug for
Combustible Sensor
Exhaust Fitting For 1/4"
OD Rigid Tubing
3/4 Conduit Hub, 2X
Dummy Plug for
CO Sensor
InletFitting For 1/4"
OD Rigid Tubing
Reset Switch
Main Circuit Board
This section describes the components of the 35-3010RK-07 sample draw detector. The sample
draw detector consists of the housing, flow system, and detection system.
2 • 35-3010RK-07 Sample-Draw Detector
Figure 1: Sample Draw Detector Compo n en t Location
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.
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
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
Oxygen
IR CH4
Hydrophobic
Filter
Inlet
Exhaust
Pump
LEL
Dummy
Plug
H2S
Flow meter
Flo w Block
Bypass
Valve
Pressu re Swi tch
CO
Dummy
Plug
Charcoal
Filter
The sample draw detector ’s flo w system consists of the INLET fitting, hydrophobic filter,
charcoal filter, pump, flowmeter, 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.
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 sample
draw detector. The INLET fitting accepts 1/4 in. rigid tubing. See “Installation” on page 8
for instructions to connect 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.
35-3010RK-07 Sample-Draw Detector • 3
Charcoal Filter
The charcoal filter is located in the top left corner of the enclosure. It is held in place by a
metal clip. The charcoal filter is placed after the H
S sensor and before the CO sensor (if
2
one is installed) in the flow system. It scrubs out interfering gases w hich may cause the
CO sensor to respond, such as H
S or certain hydrocarbons. It is included in this version
2
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 gen e rated f rom the 24 VDC supplied 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 17 for instructions to adjust this setti ng.
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 to the controller for all three channels. 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).
4 • 35-3010RK-07 Sample-Draw Detector
Flow Blocks
Both flow blocks are located in the lower right corner of the sample-draw detector. The
oxygen and H
houses the IR CH
S sensors are installed in the larger flow block. The smaller flow block
2
sensor. The flow blocks route the sampled air to each sensor.
4
EXHAUST Fitting
The EXHAUST fitting on the bottom of the housing allows the gas sample to exit the
sample draw detector. The EXHAUST fitting accepts 1/4 in. rigid tubing. See
“Installation” on page 8 for instructions to connect tubing to the EXHAUST fitting.
Detection System
The detection system consists of the IR CH4, oxygen and H2S sensors, preamp circuit
board, and the main circuit board.
IR CH
The infrared CH
Sensor
4
sensor is installed in the smaller flow block in the lower right corner. A
4
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 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.
CO Dummy Plug
The CO sensor position in the flow block is occupied by a plastic dummy plug in the
35-3010RK-07.
Hydrogen Sulfide Gas Sensor
The hydrogen sulfide gas sensor is installed in the upper right side of the flow block. It
has 4 pins which mate with sockets on the preamp circuit board.
Preamp Circuit Board
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 of the right is for the H
S sensor
2
signal. Since the CO sensor is replaced with a dummy plug in the 35-3010RK-07 the CO
sensor signal cable carries no signal in this version of the 35-3010RK.
35-3010RK-07 Sample-Draw Detector • 5
Loading...