RKI Instruments 35-3010RKA-02 User Manual
35-3010RKA-02 Sample-Draw
Part Number: 71-0212RK
Revision: E
Released: 6/18/14
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-02 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 service, 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-02 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration, Oxygen Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Calibration, H2S Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
35-3010RKA-02 Sample-Draw Detector
Overview
This manual describes the 35-3010RKA-02 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-02.
Target Gases & Detection Ranges Combustible Gas: 0 - 100% LEL
Input Power 24 VDC
Current Draw 275 mA
Output Signals 4-20 mA each channel
Table 1: Specifications
Oxygen: 0-25% volume
Hydrogen Sulfide (H
S): 0 - 100 ppm
2
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 se conds
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
WARNING: When using the 35-3010RKA-02, you must follow the instructions and
warnings in this manual to assure proper and safe opera tion of the
35-3010RKA-02 an d to minimize the ris k of personal injury. Be sure to
maintain and periodically calibrate the 35-3010RKA-02 as described in this
manual.
:
2
:
S (whichever is greater)
2
35-3010RKA-02 Sample-Draw Detector • 1
Description
Hydrophobic
Filter (AcroPak)
This section describes the components of the 35-3010RKA-02 sample-draw detector. The
sample-draw detector consists of the housing, flow system, and detection system.
LEL Transmitter
Charcoal Filter
MainCircuit Board
Oxygen
Transm itter
Reset Switch
Pum p
3/4 ConduitH ub, 2X
Exhaust Fitting F or 1/4"
OD Rigid Tubing
Inlet F itting Fo r 1/4"
OD Rigid Tubing
Amp 1
Amp 2
Preamp
Circuit
Board
Flow
Block
H2S S ensor
Oxygen Sen sor
CO Sensor
Combustible
Sensor
Figure 1: Sample-Draw Detector Component 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.
2 • 35 -3010RKA-02 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 m eter
Flow Block
Inlet
Hydrophobic
Charcoal
Filter
Pump
CO
Dummy
Plug Used
LEL
H2S
Oxygen
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 to connect tubin g 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-02 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
H
S or certain hydrocarbons. It is included in this version of the sample draw detector in
2
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 H
downscale reading at the monitor on this channel. 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-02 Sample-Draw Detec tor
S channel. This causes a
2
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 for instructions 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-02 Sample-Draw Detector • 5
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