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RKI Instruments 35-3001A-14, Operator'S Manual

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6 • 35-3001A-14 Methane Sample-Draw Detector

IR CH

4

 Amplifier

Each IR CH

4

 amplifier converts the electrical output from the IR CH

4 

sensor to a 4 to 20 mA signal that 

corresponds to the detection range and transmits the signal to a gas monitoring controller. A label on the 
amplifier indicates the detector drive current. This drive current is factory set. One amplifier is mounted on 
the top middle edge of the main circuit board. The other is mounted in the bottom left corner of the main 
circuit board. Each amplifier consists of the zero pot, span pot, controller terminal strip, detector terminal 
strip, and test points.

Figure 3:  IR CH

4

 Amplifier Component Location

Zero Pot

The zero pot is located in the upper right corner of the amplifier (see Figure 3). Use a small flat blade 
screwdriver to turn the zero pot’s adjustment screw and adjust the amplifier’s zero (fresh air) output during 
the start-up and calibration procedures. Turn the adjustment screw clockwise to increase the fresh air output 
and counterclockwise to decrease the fresh air output.

Span Pot

The span pot is located below the zero pot (see Figure 3). Use a small flat blade screwdriver to turn the span 
pot’s adjustment screw and adjust 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 plug-in style terminal 
strips, respectively. The controller terminal strip is located on the right side of the amplifier and the detector 
terminal strip is to the left of it. Both terminal strips are factory wired to the sensor and main circuit board.

Test Points

The test points are on the left side of the amplifier (see Figure 3). The test points produce a 100 mV to 500 
mV output that corresponds to the sample-draw detector’s 4 to 20 mA output. Use the test points and a 
voltmeter to measure the amplifier’s output during the start-up and calibration procedures. The black test 
point in the upper left corner is the negative (-) test point and the red test point to the left of the zero and span 
pots is the positive (+) test point.

Factory Set Pots

Sensor

Current

148mA

W

LEL

G

B

R

Test Points 

100-500 mV Range

Zero Pot

Detector 

Terminal Strip

Span Pot

Controller 
Terminal Strip

S

PWR / SIG

Summary of Contents for 35-3001A-14

Page 1: ...www rkiinstruments com 35 3001A 14 Methane Sample Draw Detector Operator s Manual Part Number 71 0603 Revision P1 Released 8 10 22 ...

Page 2: ...riodic 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 3 and 6 months but can be required more often or less often based on your usage ...

Page 3: ...placement 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 N...

Page 4: ... Detector to a Controller 9 Start Up 11 Introducing Incoming Power 11 Setting the Zero Reading 12 Maintenance 12 Preventive Maintenance 12 Troubleshooting 12 Replacing Components of the Sample Draw Detector 13 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 Zero Reading 18 ...

Page 5: ...e the risk of personal injury Be sure to maintain and periodically calibrate the 35 3001A 14 as described in this manual Table 1 Specifications Target Gases 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 Sampling Method Sample draw Sample Flow 3 0 SCFH typic...

Page 6: ...ip Factory Wired G W B W L EL G B R R OXY S AMP 2 AMP S Pilot LED Fail LED Sensor Flow Control Valve Pump Reset Switch Pressure Switch Adjustment Screw behind PCB Flowmeter B G W Interconnect Terminal Strip AMP 2 S S AMP 1 R W G OXY P W R S IG Particle Filter LEL IR Flowmeter Circuit Board Connector LEL IR Inlet Fitting Exhaust Fitting This End To Inlet Fitting 3 4 Conduit Hub INLET EXHAUST IR Amp...

Page 7: ...ttings 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 at the e...

Page 8: ... 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 board Use the flowmeter circuit b...

Page 9: ...ion occurs the pump will be shut off To reset the low flow condition and start the pump 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 ...

Page 10: ...rewdriver to turn the span pot s adjustment screw and adjust 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 ...

Page 11: ... 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 is4 3 ...

Page 12: ...g 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 tubing...

Page 13: ...nsert 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 ...

Page 14: ...n 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 White Not Used on This Version Black Red Z ER O S PA N S P W R SIG White Red Green Black Red LEL IR LEL IR AMP 2 AMP 1 AMP 1 AMP 2 P A T S 2 0 1 P A T S 2 0 1 White P A T S 1 0 1 P A T S 1 0 1 OXY IR CH4 Sensor PCB IR CH4 Sensor OXY S ensor Cu...

Page 15: ... s 4 20 mA signal should be stable by the time the controller s warmup period is over 6 Verify that the flowmeter indicates a flow rate of approximately 1 0 SCFH If necessary use the sensor flow control valve to adjust the flow rate Turn the valve s knob clockwise to increase the flow and counterclockwise to decrease the flow NOTE The following step tests for leaks in the sample line This test wil...

Page 16: ...ion also includes procedures to troubleshoot the sample draw detector replace components of the sample draw detector adjust the low flow setting and remove the particle filter s tubing stub Preventive Maintenance This section describes a preventive maintenance schedule to ensure the optimum performance of the sample draw detector It includes daily and biannual procedures Daily Visual Checks 1 Veri...

Page 17: ...n procedure The sensor requires frequent calibration Probable causes The calibration cylinder is low out dated or defective If a demand flow regulator calibration kit is used the demand flow regulator is not functioning properly The sample draw detector s flow rate is too low because of an obstructed sample line failed pump etc The sample draw detector is malfunctioning Recommended action 1 Verify...

Page 18: ...1 Turn off the controller 2 Turn off power to the controller 3 Open the housing door of the sample draw detector 4 Remove the detector and controller plug in terminal strips by grasping the sides of the strips with your fingers Let the terminal strips hang by their connected wires while you replace the amplifier 5 Unscrew the screw in the lower left corner of the amplifier and remove the screw loc...

Page 19: ... from the sample draw detector 5 Install the new filter Be sure the side of the filter marked INLET is connected to the elbow that is connected to the inlet fitting 6 Turn on power to the controller 7 Turn on the controller 8 Verify that the flow rate is approximately 1 0 SCFH then close the housing door Replacing the Particle Filter 1 Turn off the controller 2 Turn off power to the controller 3 I...

Page 20: ...the sample draw detector goes into low flow alarm before you can adjust the flow down to 0 6 SCFH adjust the pressure switch adjustment screw 1 4 turn clockwise then attempt to set the flow again Repeat this step until you are able to adjust the flow to 0 6 SCFH NOTE The pressure switch adjustment screw is accessible through a circular cutout in the flowmeter circuit board 2 Slowly turn the pressu...

Page 21: ...ome out with the tube nut Be careful not to lose the O ring that may come out with the tubing stub If you do lose the O ring or if it is damaged see Parts List on page 20 for the spare part number 3 Push the tubing stub up and out of the front ferrule being careful not to lose the ferrule set If you do lose the ferrule set or if it is damaged see Parts List on page 20 for the spare part numbers 4 ...

Page 22: ...is procedure describes calibration using a demand flow regulator Preparing for Calibration 1 Follow the instructions in the controller s operator s manual for entering calibration mode 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 2 Screw the regulator into a zero air calibration cylinder 3 Open the housing door ...

Page 23: ...the sample draw detector s inlet line 3 Allow the sample draw detector to draw sample for one minute 4 When the reading on the voltmeter stabilizes verify that the reading matches the response reading 2 mV you determined earlier 5 If necessary use the span potentiometer on the amplifier to adjust the reading to match the correct response reading 6 Disconnect the sample tubing from the inlet line 7...

Page 24: ...l mist filter 33 0165RK Hydrophobic filter 33 0167RK Particle filter 61 5039RK CH4 Infrared CH4 sensor plug in type vol range 71 0603 Operator s Manual 35 3001A 14 Sample Draw Detector 81 0012RK 01 Calibration cylinder 50 LEL methane in air 34 liter steel 81 0012RK 05 Calibration cylinder 50 LEL methane in air 58 liter 81 0076RK 01 Zero air calibration cylinder 34 liter steel 81 0076RK 03 Zero air...

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