RKI Instruments 35-3010RKA-01 User Manual

35-3010RKA-01 Sample-Draw

Part Number: 71-0211RK
Revision: G
Released: 9/24/13

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.

35-3010RKA-01 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.

35-3010RKA-01 Sample-Draw Detector

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Calibration, LEL Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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

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

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Calibration, Oxygen Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

Calibration, CO and H2S Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

35-3010RKA-01 Sample-Draw Detector

Overview

This manual describes the 35-3010RKA-01 sample-draw detector. This manual also
describes how to install, start up, maintai n, 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 35-3010RKA-01.

Target Gases & Detection Ranges Combustible Gas: 0 - 100% LEL

Input Power 24 VDC
Current Draw 275 mA

Table 1: Specifications

Oxygen: 0-25% volume
Carbon Monoxide (CO): 0 - 300 ppm
Hydrogen Sulfide (H

S): 0 - 100 ppm

2

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 Combustible Gas

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

Hydrogen Sulfide (H2S):
± 5% of reading or ± 2 ppm H
Carbon Monoxide (CO)

± 5% of reading or ± 5 ppm CO (whichever is greater)

WARNING: When using the 35-3010RKA-01, you must follow the instructions and

warnings in this manual to assure proper and safe opera tion of the
35-3010RKA-01 an d to minimize the ris k of personal injury. Be sure to
maintain and periodically calibrate the 35-3010RKA-01 as described in this
manual.

:

2

:

S (whichever is greater)

2

:

35-3010RKA-01 Sample-Draw Detector • 1

Description

Hydrophobic

Filter (AcroPak)

This section describes the components of the 35-3010RKA-01 sample-draw detector. The
sample-draw detector consists of the housing, flow system, and detection system.

Ch a rc oal Filt er

Main Circuit Board

Reset Switch

Amp 1

Pump

3/4 Conduit Hub, 2X

Exhaust Fitting For 1/4"

OD Rigid Tubing

Inlet Fitting For 1/4"

OD Rigid Tubing

Figure 1: Sample-Draw Detector Component Location

Amp 2

Preamp
Circuit

Board
Flow
Block

H2S Dummy
Plug

Oxygen Dummy Plug

CO Sensor
Combustible
Sensor

Housing

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
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.

2 • 35 -3010RKA-01 Sample-Draw Detec tor

Flow System

Filter

The sample-draw detector’s flow system consists of the INLET fitting, hydrophobic filter,
charcoal filter, pump, flowmeter, bypass valve, status lights, pressure switch, flow block,
and EXHAUST fitting (see Figure 1). Figure 2 illustrates how the gas sample moves
through the flow system.

Bypass

Valve

Exhaust

Pressure Switch

Flow meter

Flow Block

H2S

Oxygen

Inlet

Hydrophobic

Charcoal

Filter

Pump

CO

LEL

Figure 2: Sample-Draw Detector Flow 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.

35-3010RKA-01 Sample-Draw Detector • 3

Charcoal Filter

The charcoal filter is located above the LEL transmitter. It is held in place by a metal clip.
The charcoal filter is placed after the H

S sensor and before the CO sensor in the flow

2

system. It scrubs out interfering gases which may cause the CO sensor to respond, such as

S or certain hydrocarbons. Replace the charcoal filter when false high CO readings are

H

2

noticed, especially in the presence of H

S.

2

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 H

S and CO channels. This causes

2

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 LEL or oxygen channels.

4 • 35 -3010RKA-01 Sample-Draw Detec tor

Flow Block

The flow block is located in the lower right corner of the sample-draw detector. All the
sensors are installed in the flow block. The flow block routes the sampled air to each
sensor.

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, LEL and oxygen transmitters, preamp
circuit board, and the main circuit board.

Combustible Gas Sensor

The combustible gas sensor is installed in the lower left of the flow block. The combustible
gas sensor includes the sensing elements, flame arrestor, connector, and sensor leads.

Sensing Elements

Two sensing elements are protected within the sensor assembly. Through a series of
thermal and electronic reactions, these elements produce an output that is pr o portional to
the detection range of the sample draw detector. The LEL transmitter converts the output
to a 4 - 20 mA signal which can be us ed by a recording or monitoring device.

The porous flame arrestor allows the gas sample to enter the sensor assembly and contact
the sensing element. The flame arrestor also contains sparks within the sensor.

Connector

The top of the sensor includes five pins that plug into the socket connector. This connector
allows you to replace the sensor without disconnecting the wiring. The sensor leads are
soldered to the connector.

Sensor Leads

Four color-coded leads extend from the connector. The leads allow you to connect the
combustible gas sensor to the main circuit board.

Oxygen Sensor

The oxygen sensor is installed in the low e r right of the flow block. The oxygen sensor
includes the oxygen cell, connector, and sensor leads.

Oxygen Cell

The oxygen cell is protected within the sensor assembly . Thr o ugh a series of chemical and
electronic reactions, the cell produces a millivolt output that is proportional to the
detection range of the sample-draw detector. The oxygen transmitter converts the output
to a 4 - 20 mA signal which can be us ed by a recording or monitoring device.

Connector

The cable that extends from the sensor terminates in a socket that plugs into a matching
7-pin male connector. The socket and connector allow yo u to replace the sensor without
disconnecting the wiring. The sensor leads are soldered to the male connector.

Sensor Leads

Two color-coded leads extend from the connector. The leads allow you to connect the
oxygen sensor to the main circuit board.

35-3010RKA-01 Sample-Draw Detector • 5

LEL Transmitter

Zero Pot

Carbon Monoxide Sensor

The carbon monoxide gas sensor is installed in the upper left side of the flow block. It has
4 pins which mate with sockets in the preamp circuit board.

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 in th e preamp circuit board.

Interconnect

Terminal Strip

Test Point TP-

TP -

BATT

+

FB

4/20

Oxygen
Transmitter

+

24V

TP +

Sensor Terminal
Strip

Test Point TP+

Test Point TP-

ZERO

Test Point TP+

SPAN

OXY

TOXIC
OXY
TOXIC

WBK

RD

G

Interconnect

Transmitter Type Selector,

Terminal S tri p

Set To OXY

Span Pot

Zero Pot

Span Pot

Figure 3: LEL & Oxygen Transmitters

LEL Transmitter

The LEL 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.

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.

Oxygen Transmitter

The oxygen transmitter is mounted to the right of th e LEL transmitter and ab ove the main
circuit board. The amplifier includes the amplifier type selector, two internally wired

6 • 35 -3010RKA-01 Sample-Draw Detec tor

terminal strips, span pot, zero pot, and test points.

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.

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.

35-3010RKA-01 Sample-Draw Detector • 7

Reset

Switch

Pilot LED

Main Circuit Board

Pump Termin al St ip

Pressure Switch

Fail LED

Flowm eter

Flow Adjust Pot

Low Flow Adjust

Relay

Test Point CAL - 1

Test Point CAL + 1

Test Point CAL - 2

Test Point CAL + 2

Interconnect Terminal
Strip

AC Termi nal
Strip Not Used

Zero Span Zero

Amp 1

(CO)

Sensor/Transmitter

Termina l S trip

Span

Amp 2

(H2S)

Figure 4: 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 4).

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.

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.

8 • 35 -3010RKA-01 Sample-Draw Detec tor

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.

2

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

S channel. A 100 mV - 500 mV output is availab le at each set o f test points for

2

use during calibration.

Pump Terminal Strip

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

“Wiring the Sample-Draw Detector” on page 11 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 H

S

2

and CO channels which will cause a downscale reading at the controller or recording
device.

NOTE: There is no flow fail indication for the LEL and oxygen channels on the

35-3010RKA-01 Sample Draw Adapter.

Reset Switch

A small reset button is located in approximately 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 start the pump again, press and hold the reset switch for about 2 seconds,
then release.

35-3010RKA-01 Sample-Draw Detector • 9

Installation

12.55

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. 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 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.

14.94

15.44

3/4" Conduit Hub, 2X

14.55

10.00

Door Latch

Ø .31 x .50 slot, 4X

.18

8.31

Tube Fitting for 1/4"

OD tube, 2X

Figure 5: Mounting the Sample-Draw Detector

2. Clos e 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 loo sen the screw that secures one of the mounting feet to the housing, then
rotate the mounting foot 180 degrees (see Figure 3).

4. Tighten the screw that secures the mounting foot to the housing.

10 • 35-3010RKA-01 Sample-Draw Detector

5. Repeat steps 3 and 4 for the remaining three mounting feet.

6. Position the sample-d raw housing on a vertical surf ace at eye level (4 1/2 to 5 feet
from the floor).

7. Ins ert 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 r educe response time, keep the

incoming sample line as short as possibl e.

3. Attach rigid sample tubing to the EXHAUST fitting.

4. Route the opposite end of the tubing to an open area where the sample can safely
disperse.

Wiring the Sample-Draw Detector

WARNING: Always verify that the power source is OFF before you make wiring

connections.

1. Turn off the controller.

2. Turn off or unplug icoming power to the controller.

3. Unlatch and op en the housing door of the sample-draw de tector.

4. Guide a ten-conductor 18 gauge, shielded cable or ten 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 6.

6. Close and latch the housing 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 o pposite end of th e drain wire at the device .

7. Route the cable or wires in conduit leadin g from the sample-draw detector to the
monitoring device and power.

8. Connect the drain wire to an available chassis ground at the device end. RKI
controllers typically have a ground stud that can be used to ground the cable’s drain
wire.

35-3010RKA-01 Sample-Draw Detector • 11

Sample Draw Housing

Main Circuit Board

Interconnect Terminal Strip

(Controller Transmitter

Oxygen

Terminals)

(Controller Transmitter

24 VDC

4-20 (Feedback)

CO

Terminals)

-

+

24 VDC +

S (4/20 mA)

4/20 Feedback
24 VDC +

4/20 Feedback
+

-

Figure 6: Extern al (Field) Wiring, Sa mple-Draw Dete ctor

LEL

24 VDC

H2S
(Controller Transmitter
Terminals)

(Controller Transmitter
Terminals)

12 • 35-3010RKA-01 Sample-Draw Detector

Pump
Factory
Wired

LEL Sensor

Connector

Black
Green

White

Red

P/N 57 -1 05 0R K

REV. 0

TP+

SP AN Z ER O

TP-

GND
24V
4-20

POWER/SIG

RED
WHT

INSTRUMENTS

GRN

SENSOR

BLK

Pressure Switch
Facto r y Wire d

ZERO

SPAN

OXY
TOXIC

TP -

TOXIC

TP +

OXY

GFBBK WRD

+

+

24V4/20

BATT

Green

White

LEL

Detector

CO and H2SSensors Plu g Into

FarSide of Preamp

Circuit Board

Figure 9: Internal (Factory) Wiring, Sample-Draw Det ector

CO

Oxygen Sensor

H2S

35-3010RKA-01 Sample-Draw Detector • 13

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 controller is on and operating properly.

5. Verify that the Pilot light is on at the sa mple draw detector.

6. Verify tha t 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 the sample 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 prese nce of combu stible gas, hydr ogen sulfide, car bon monoxid e, or

an abnormal oxygen condition (not 20.9%) in the monitori ng environment, use the
calibration kit and the zero air calibration cylinder to introduce “fresh air” to t he
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 combustible gas, H

content, 20.9%).

2. Open the housing door.

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

4. Check the zero reading for each channel.

• For the LEL channel, plug the voltmet er leads into the test points on the LEL

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-.

S, or CO and of normal oxygen

2

• For the CO channel, plug the voltmeter into the test points in the AMP 1 section of

the main circuit board. Plug the positive lead into the test point labeled CAL+1;
plug the negative lead into the test point labeled CAL-1.

•For the H

14 • 35-3010RKA-01 Sample-Draw Detector

S channel, plug the voltmeter into the test points in the A MP 2 section

2

Operation

of the main circuit board. Plug the positive lead into the test point labeled CAL+2;
plug the negative lead into the test point labeled CAL-2.

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

6. If necessary, use a s ma ll flat-blade screwdriver to adjust the zero pot until the
voltmeter reading is 100 mV (± 2 mV).

7. 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. In addition, the CO a nd H

the sample draw detector resulting in a failure indication for the CO a nd H
the controller. If a low flow alarm occurs, press the pump reset switch for about 2 seconds

to restart the pump, turn off the Fail LED, and resume proper sensor signal transmission
to the controller. If the condition continues, find the cause of the reduced flow, correct it,
and restart the pump with the pump reset switch. A flow reduction can be caused by a
flow blockage, a leak in the flow system, a malfunctioning pressure switch, or a
malfunctioning pump.

S sensor signals to the controller will be interrupted by

2

S channels at

2

NOTE: There is no flow fail indication for the LEL and oxygen channels on the 35-

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. Ve ri fy that the pilot light is on.

2. Verify that the flowmeter indicates a flow rate of approximately 1.2 SCFH.

3. V erify a r eading of 0%LEL fo r the combustible channel (100 mV at the LEL trans mitter

3010RKA-01.

If necessary use the bypass valve or flow ad just potentiometer to adjust the flow rate
to 1.2 SCFH.

test points), 20.9% for the oxygen channel (434 mV at the oxygen transmitter test

35-3010RKA-01 Sample-Draw Detector • 15

points), 0 ppm for the CO channel (100 mV at the amp 1 test points), and 0 ppm for the
H

S channel (100 mV at the amp 2 test points). Investigate si gnificant changes in the

2

reading.

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 monitoring device. Take appropriate action

to avoid this, such as entering the calibration mode at the monitoring device.

1. Verify tha t the controller is reading 0 for the combustible, CO, and H

S channels and

2

20.9 for the oxygen channel.
If the reading is not 0 on the combustible, CO, or H

S channels or 20.9 on the oxygen

2

channel, set the zero r e ading a s described i n “Start Up” on page 14, then continue this
procedure.

2. Assemble the calibra tion kit as described in the Calibration section of this ma nual.
Use of a 4-gas cylinder is recommended so that all channels may be checked at once.

Performing the response test

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

regulator.

1. Screw the regulator into the calibration cylinder.

2. Connect the c ali brat io n tu bi ng fr om the r e gul ator 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 each channel at the
controller stabilizes within ± 10% of the concentration of the test sa mple. If the
reading is not within ± 10% of the test sample, calibrate the sample-draw detecto r as
described in the Calibration section of this manual.

4. Remove the calibrati on tubing from the inlet line, then reconnect the inlet line.

Quarterly

Calibrate the sample-draw detector as described in the “Calibration” section on page 14.

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 monitorin g d e vice if it exhibits any problems.

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

16 • 35-3010RKA-01 Sample-Draw Detector

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. “Installation” on
page 10 describes detector wiring connections.

4. Calibrate the problem channel or channels as described in the Calibration 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. Verify that the calibration cylinder contains an adequate supply of a fresh test sample.

2. If necessary, set the co rrect flow rate with th e bypas s valve or flow adjust
potentiometer.

3. If you cannot set the correct flow rate, check the sample line for obstructions or kinks.

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

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

35-3010RKA-01 Sample-Draw Detector • 17

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 Combustible Sensor

1. Turn off incoming po wer.

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. Unplug the connector from the sensor.

5. Verify that you are using the correct replacement sensor (NC-6245 is printed on the
sensor), then plug the sensor into the connector.

6. Place the sensor in the combustible gas 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, LEL Detector” on
page 20.

Replacing the Oxygen Sensor

1. Turn off incoming po wer.

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. Unplug the connector from the socket th at lead s 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 22.

Replacing the Carbon Monoxide Sensor

1. Turn off incoming po wer.

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

3. Unscrew the 5 screws that retain the preamp circuit board.

4. Lift the preamp circuit board away from the flow block.
Be careful not to pull on the cables that connect the preamp circuit to the main circuit

board.
There is a foam gasket in the bottom of each flow cavity beneath the circuit board.

Make sure the gaskets stay in place.

5. Pull the CO sensor off the preamp circuit boar d. It is located in the amp 1 position (left
side) of the preamp circuit board.

6. Plug the new sensor into the preamp board.

18 • 35-3010RKA-01 Sample-Draw Detector

7. Reinstall the preamp circuit board with the sensors onto the flow block.

8. Turn on incoming power.

9. Calibrate the replacement sensor as described in “Calibration, H

S and CO Detectors”

2

on page 23.

Replacing the Hydrogen Sulfide Sensor

1. Turn off incoming po wer.

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

3. Unscrew the 5 screws that retain the preamp circuit board.

4. Lift the preamp circuit board away from the flow block.
Be careful not to pull on the cables that connect the preamp circuit to the main circuit

board.
There is a foam gasket in the bottom of each flow cavity beneath the circuit board.

Make sure the gaskets stay in place.

5. Pull the H

S sensor off the preamp circuit board. It is located in the amp 2 position

2

(right side) of the preamp circuit board.

6. Plug the new sensor into the preamp board.

7. Reinstall the preamp circuit board with the sensors onto the flow block.

8. Turn on incoming power.

9. Calibrate the replacement sensor as described in “Calibration, H

S and CO Detectors”

2

on page 23.

Replacing the Hydrophobic Filter

1. Turn off or unplu g power to the controller.

2. Locate the hydrophobic filter. It is just to the left of the main circuit board.

3. Grasp 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.

Replacing the Charcoal Filter

1. Turn off or unplu g power to the controller.

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 adjust potenti om e ter (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

35-3010RKA-01 Sample-Draw Detector • 19

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 until 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 3 and 4 if necessary.

4. Use the flow adjust potenti om e ter (VR1 ) to set the flow to 1.2 SCFH.

5. Make 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 sample
draw detector.

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 frequency of every 6 months is adequate for the sample draw detector.

If the application is very demanding, for example if the environment is not well
controlled, then more frequent calibration than every 3 months may be necessary for the
sample draw detector.

Calibration, LEL Detector

This section describes how to calibrate the LEL 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 4-gas 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. Set a voltmeter to measure in the millivolt (mV) range.

3. Plug the voltmeter into the test po ints on the LEL transmitter. Plug the positive lead
into the test point labeled TP+; plug the ne gative lead into the test point labeled TP-.

20 • 35-3010RKA-01 Sample-Draw Detector

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

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

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

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. Screw the regulator into the zero air calibration cyli nd er.

2. Connect the 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 fl ow for one minute.

5. Verify a voltmeter reading of 100 mV ± 2 mV at the test points as described in the
Preparing for Calibration section above.

6. If necessary, use a s ma ll flat-blade screwdriver to adjust the zero pot until the
voltmeter reading is 100 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.

Setting the Response Reading

1. Screw the regulator into the 4-gas calibration cylinder.

2. Connect the sample tubing from the regulator to the inlet line at or near the sa mple­draw detector’s INLET fitting.

3. Allow the calibra tion gas to flow for one minute.

4. Check the mV output on the LEL transmitter test points and verify that the reading
matches the response reading (±2 mV) you determined earlier.

5. If necessary, use the span pot on the LEL transmitter to adjust the reading to match the
correct response reading.

6. Disconnect the sample tubi ng 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.

Returning to Normal Operation

1. Remove the voltmeter leads from the test points.

2. Reconnect the in coming 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.

35-3010RKA-01 Sample-Draw Detector • 21

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 4-gas calibration cylinder to set the zero reading. A 4­gas cylinder is used to set the zero since it is alreayd usd to calibrate the LEL, CO,
and H

the zero reading.

Prepari ng for Ca libration

CAUTION: This procedure may cause alarms at the controller. Take appropriate action to avoid

S channels. A 100% nitrogen calibration cylinder could also be used to set

2

this, such as entering the calibration mode at the controller.

1. Open the housing door.

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

3. 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-.

4. 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 12% and a fullscale setting of 25%, the
correct output for the oxygen test points is 292 mV.

292 (mV) = (12/25) X 400 +100

Setting the Zero Reading

NOTE: The 4-gas calibration cylinder included in the calibration kit may be used to zero

the oxygen channel. Keep in mind that the oxygen concentration in that cylinder
is 12%, not 0%. Be sure to set the controller appropriately.

1. Screw the regulator into the 4-gas calibration cylinder.

2. Connect the calibration kit sample tubing to the regulator.

3. Allow the sample-draw detector to respond to the calibrating sample for
approximately 1 minute.

4. After one minute, check the mV output on the oxygen transmitter test points and
verify that the reading matches the response reading (±2 mV) you determined earlier
(292 mV for 12% oxygen).

5. If necessary, use the span pot on the transmitter to adjust the reading to match the
correct response reading.

6. Disconnect the sample tubing from the inlet line.

22 • 35-3010RKA-01 Sample-Draw Detector

7. Unscrew the regulator from the 4-gas calibra tion cylinder.

8. For convenience, leave the regulator at tached 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. Screw the regulator into the zero air calibration cyli nd er.

2. Connect the 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 fl ow 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 s ma ll 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 in coming 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.

Calibration, H2S and CO Detectors

This section describes how to calibrate the H2S and CO detectors in the sample-draw
detector. It includes procedures to prepare for calibration, set the zero reading for each

channel, set the response reading for each channel, and return to normal operati o n.

NOTE: This procedure describes calibration using a demand flow regulator, a zero air

calibration cylinder, and a 4-gas 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.

35-3010RKA-01 Sample-Draw Detector • 23

1. Open the housing door.

2. Set a voltmeter to measure in the milli volt (mV) range. It will be used in the
calibration of the CO and H

S channels.

2

• When checking the mV output of the CO channel, plug the voltmeter leads into

the test points in the AMP 1 section of the main circuit board. Plug the positive
lead into the test point labeled CAL+1; plug the negative lead into the test point
labeled CAL-1.

• When checking the mV output of the H

S channel, plug the voltmeter leads into

2

the test points in the AMP 2 section of the main circuit board. Plug the positive
lead into the test point labeled CAL+2; plug the negative lead into the test point
labeled CAL-2.

3. Use the following formula to determine the correct test points output for the CO and
H

S calibrating sample.

2

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

For example, with a calibrating sample of 25 ppm H
ppm H

S, the correct output for the H2S test points is 200 mV.

2

S and a fullscale setting of 100

2

200 (mV) = (25/100) X 400 +100

Setting the Zero Reading

1. Screw the regulator into the zero air cylinder.

2. Connect the 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 1 minute.

5. Verify a voltmeter reading of 100 mV ± 2 mV at the AMP 1 and AMP 2 test points for
the CO and H

6. If necessary, use a small flat-blade screwdriver to adjust the zero pot for the CO or H
channel until the voltmeter reading is 100 mV ± 2 mV.

S channels as described in the Prepari n g for Cal ibr at io n sectio n above.

2

2

S

7. Disconnect the sample tubing from the inlet line.

8. Unscrew the regulator from the zero air cylinder. Leave the sample tubing connected
to the regulator.

Setting the Response (Span) Reading

1. Screw the regulator into the 4-gas calibration cylinder.

2. Connect the sample tubing from the regulator to the inlet line at or near the sa mple
draw detector’s INLET fitting.

3. Allow the calibration gas to flow for 1 minute.

4. Check the mV output on the AMP 1 test poi nts for CO and verify that the reading
matches the response reading (±2 mV) you determined earlier.

5. If necessary, use the A MP 1 span pot to adjust the reading to match the correct
response reading.

6. Check the mV output on the AMP 2 test poi nts for H
matches the response reading (±2 mV) you determined earlier.

7. If necessary, use the A MP 2 span pot to adjust the reading to match the correct

24 • 35-3010RKA-01 Sample-Draw Detector

S and verify that the reading

2

Parts List

response reading.

8. Disconnect the sample tubing from the sample draw detector’s inlet line.

9. Unscrew the regulator from the calibration cylinder.

NOTE: For convenience, leave the regulator connected to the sample tubing.

Returning to Normal Operation

1. Remove the voltmeter leads from the test points.

2. Reconnect the in coming sample line.

3. Wait 1 to 2 minutes to allow the calibration gas to be drawn out and the readings to
stabilize.

4. Close the housing door.

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

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 x 5/16, specify length, (for calibration kit)
07-0034RK Sealing gasket, for CO and H

S flow block cavities

2

30-0610RK Pump
33-0171RK Hydrophobic filter (AcroPak)
33-6095RK Charcoal filter, CF-188
65-0601RK Oxygen sensor
81-0076RK-01 Zero air calibration cylinder (34 liter)
81-0154RK-04 4-gas calibration gas cylinder, 50% LEL methane/12% oxygen/25

ppm H

S/50 ppm CO, 34 liter

2

81-1055RK Regulator, demand flow, for 17 and 34 liter steel cylinders
ES-1531-CO CO sensor
ES-1537-H2S H

S sensor

2

NC-6245 Combustible sensor

35-3010RKA-01 Sample-Draw Detector • 25