RKI Instruments 35-3001A-01-01 Operator'S Manual Download Page 1

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35-3001A-01-01

Methane Sample-Draw Detector

Operator’s Manual

Part Number: 71-0310RK

Revision: A

Released: 8/7/17

Summary of Contents for 35-3001A-01-01

Page 1: ...www rkiinstruments com 35 3001A 01 01 Methane Sample Draw Detector Operator s Manual Part Number 71 0310RK Revision A Released 8 7 17 ...

Page 2: ...eriodic calibration and maintenance of the detector is essential for proper operation and correct readings Please calibrate and maintain this detector regularly Frequency of calibration depends upon the type of use you have and the sensor types Typical calibration frequencies for most applications are between 6 and 12 months but can be required more often or less often based on your usage ...

Page 3: ...replacement costs local repair costs transportation costs or contingent expenses incurred without our prior approval 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...

Page 4: ... Draw Detector to a Controller 9 Start Up 11 Introducing Incoming Power 11 Setting the Zero Reading 11 Maintenance 12 Preventive Maintenance 12 Troubleshooting 13 Replacing Components of the Methane Sample Draw Detector 14 Adjusting the Low Flow Setting 16 Removing the Particle Filter s Tubing Stub if Necessary 17 Calibration Frequency 18 Calibration 18 Preparing for Calibration 18 Setting the Zer...

Page 5: ... safe operation of the 35 3001A 01 01 and to minimize the risk of personal injury Be sure to maintain and periodically calibrate the 35 3001A 01 01 as described in this manual Table 1 Specifications Target Gas and Detection Range Methane 0 100 LEL Input Power 24 VDC Nominal 18 5 VDC 30 VDC Construction housing Fiberglass polyester NEMA 4X Dimensions 8 5 in H x 6 5 in W x 4 25 in D Weight 4 5 lbs S...

Page 6: ...or PCB IR CH4 Flow Block W L E L G B R Pilot LED Fail LED Sensor Flow Control Valve W Interconnect Terminal Strip Pump Reset Switch Flowmeter B G AMP 2 S S AMP 1 R W G OXY Hydrophobic Filter Particle Filter Flowmeter Circuit Board Connector LEL IR IR CH4 Sensor inside block Inlet Fitting Exhaust Fitting This End To Inlet Fitting 3 4 Conduit Hub INLET EXHAUST Pump Connector IR Amplifier AMP 2 AMP W...

Page 7: ...ample fittings accept 1 4 in rigid tubing See the Installation section on page 7 to connect tubing to the sample fittings Particle Filter A particle filter with a tubing stub on one end is shipped with the instrument but it is not factory installed If the particle filter is installed directly to the inlet fitting the tubing stub must be used If the particle filter is installed somewhere else like ...

Page 8: ...ht corner of the main circuit board Use the pump connector to connect the pump to the main circuit board NOTE The pump is factory wired to the main circuit board See Installation on page 7 for all wiring procedures related to the sample draw detector Flowmeter Circuit Board Connector The flowmeter circuit board connector is a six position connector in the upper left corner of the main circuit boar...

Page 9: ...again press and hold the pump reset switch for about 2 seconds then release Hydrophobic Filter The hydrophobic filter is located toward the bottom left of the main circuit board The filter prevents particulates and water in the incoming gas sample from damaging the flow and detection systems Replace the filter when it appears dirty discolored or clogged Pump The pump is mounted to the right side o...

Page 10: ...djust the amplifier s gas response output during the calibration procedure Turn the adjustment screw clockwise to increase the span output and counterclockwise to decrease the span output CAUTION The amplifier includes additional pots They are factory set Do not adjust them Controller and Detector Terminal Strips The controller terminal strip and detector terminal strip are three and four position...

Page 11: ...owing when you select the mounting site Is there enough room to open the housing door and make wiring and tubing connections at the bottom of the housing Make sure there is sufficient room to perform start up maintenance and calibration procedures Are the flowmeter and status LEDs visible Figure 4 Outline and Mounting Dimensions Ø 30 x 50 4X MOUNTING 78 1 13 40 Pilot Fail 85 80 4 50 NOTE Housing i...

Page 12: ...ng components 4 Connect a length of sample tubing to the other side of the particle filter and route it to the sampling area 1 4 O D rigid polypropylene Teflon or flexible polyurethane tubing may be used RKI Instruments Inc recommends using either 1 4 O D x 1 8 I D or 1 4 O D x 0 170 I D tubing based on your length requirements See Specifications on page 1 for maximum tubing lengths based on tubin...

Page 13: ...rt to seal the connection between the tubing and the inlet fitting 3 Hand tighten the nut on the exhaust fitting so the ferrules clamp on the tubing If the tube nut is removed see Figure 6 for the arrangement of the fitting components 4 Route the opposite end of the tubing to an open area where the sample can safely disperse or to an exhaust duct See Specifications on page 1 for maximum tubing len...

Page 14: ...ing the Sample Draw Detector to a Controller 9 If shielded cable is used connect the cable s drain wire to an available chassis earth ground at the controller RKI controllers typically have a ground stud that can be used to ground the cable s drain wire Not Used on This Version S P WR SI G ZE RO SP AN OXY LEL IR Red White P A T S 2 0 1 P A T S 2 0 1 AMP 1 AMP 1 OXY LEL IR Controller or Recording D...

Page 15: ... this test 7 Verify that the incoming sample line is not leaking To test the sample line press and hold the reset switch and plug the open end of the sample line with your thumb If the flowmeter ball drops to the bottom of the flowmeter the incoming sample line is not leaking 8 Remove your thumb from the sample line release the reset switch and verify the flowmeter returns to a normal flow rate 9 ...

Page 16: ...display reading of 0 LEL at the controller or a reading of 100 mV at the amplifier test points Investigate significant changes in the display reading Monthly Response Test This procedure describes a test to verify that the sample draw detector responds properly to the target gas NOTE To reduce the response time of this test use a short incoming sample line If the sample draw detector s sample line...

Page 17: ...a safe place Biannual Calibration Calibrate the sample draw detector as described in Calibration on page 18 Troubleshooting The troubleshooting guide describes symptoms probable causes and recommended action for problems you may encounter with the sample draw detector NOTE This troubleshooting guide describes sample draw detector problems only See the controller Operator s Manual if the controller...

Page 18: ...ent demand flow regulator to determine if the original one is functioning properly 3 If necessary set the correct flow rate with the sensor flow control valve 4 If you cannot set the correct flow rate check the sample line for obstructions or kinks 5 If the calibration response difficulties continue replace the sensor as described later in this section 6 If the calibration response difficulties co...

Page 19: ...rom the main circuit board 7 Install the new amplifier in the same orientation as the old amplifier See Figure 1 8 Reinstall the screw lock washer and flat washer you removed in step 5 9 Install the detector and controller plug in terminals strips into their sockets on the new amplifier If controller leads or detector cable leads were removed from the plug in terminal strips during this procedure ...

Page 20: ...m the particle filter 2 Disconnect the particle filter from the tubing stub 3 Install the new particle filter onto the tubing stub Be sure the arrow on the particle filter is pointing toward the inlet fitting 4 Reinstall the tubing routed to the sampling area 4 If the particle filter is installed at the end of the inlet line 1 Remove the particle filter from the tubing stub 2 Install the new parti...

Page 21: ...ckwise Repeat steps 3 and 4 if necessary 5 Use the sensor flow control valve to set the flow to 1 0 SCFH 6 Make sure the sample draw detector s Fail LED is off Removing the Particle Filter s Tubing Stub if Necessary A short tubing stub comes factory installed in the particle filter It is used for connecting the particle filter to the inlet fitting If you have installed the particle filter and no l...

Page 22: ...alibration frequency of every 6 months If an application is not very demanding for example detection in a clean temperature controlled environment where calibration adjustments are minimal at calibration then a calibration frequency of every 9 to 12 months is adequate If an application is very demanding for example if the environment is not well controlled then more frequent calibration than every...

Page 23: ...ext section Setting the Response Reading 5 Disconnect the sample tubing from the inlet line 6 Unscrew the regulator from the zero air calibration cylinder Setting the Response Reading 1 Screw the regulator into the methane calibration cylinder 2 Connect the sample tubing from the demand flow regulator to the sample draw detector s inlet line 3 Allow the sample draw detector to draw sample for one ...

Page 24: ...K Pump 33 0165RK Hydrophobic filter 33 0167RK Particle filter 57 1053RK 10 Amplifier 61 5039RKP CH4 IR CH4 sensor 0 100 LEL 71 0310RK Operator s Manual 35 3001A 01 01 Sample Draw Detector 81 0012RK 01 Calibration cylinder 50 LEL methane in air 34 liter steel 81 0012RK 03 Calibration cylinder 50 LEL methane in air 103 liter 81 0076RK 01 Zero air calibration cylinder 34 liter steel 81 0076RK 03 Zero...

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