RKI Instruments 35-3001A-08 Operator'S Manual Download

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35-3001A-08

Combustible Gas

Sample-Draw Detector

Operator’s Manual

Part Number: 71-0589

Revision: P1

Released: 2/17/22

Summary of Contents for 35-3001A-08

Page 1: ...www rkiinstruments com 35 3001A 08 Combustible Gas Sample Draw Detector Operator s Manual Part Number 71 0589 Revision P1 Released 2 17 22 ...

Page 2: ...m 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 Typical calibration frequencies for most applications are between 3 and 6 months but can be required more often or less often based on your usa...

Page 3: ...removal or 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...

Page 4: ...er 19 Setting the Zero Reading 20 Maintenance 20 Preventive Maintenance 20 Troubleshooting 21 Replacing Components of the Sample Draw Detector 22 Adjusting the Low Flow Setting 26 Removing the Particle Filter s Tubing Stub if Necessary 27 Calibration Frequency 28 Calibration LEL Sensor 28 Preparing for Calibration 28 Setting the Zero Reading 29 Setting the Response Reading 29 Returning to Normal O...

Page 5: ...le gas 0 100 LEL Carbon Monoxide 0 300 ppm 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 typical with no inlet or exhaust line Flow to Sensor 1 0 SCFH nominal Low Flow Setpoint 0 6 0 1 SCFH Maximum Recommended Inlet Exhaust Line Length for 1 4 O ...

Page 6: ...8 you must follow the instructions and warnings in this manual to assure proper and safe operation of the 35 3001A 08 and to minimize the risk of personal injury Be sure to maintain and periodically calibrate the 35 3001A 08 as described in this manual ...

Page 7: ... rr en t 14 8m A W O X Y G E N G B Flow Baffle LEL Flow Block LEL Sensor H2S Flow Block R S S Pilot LED Fail LED Pressure Switch Adjustment Screw behind PCB Flowmeter Pump Reset Switch B G S A MP 1 S R A MP 2 W G OX Y This End To Inlet Fitting Pump Connector Particle Filter Interconnect Terminal Strip Sensor Flow Control Valve Flowmeter Circuit Board Connector W W LE L I R H2S Amplifier Inlet Fitt...

Page 8: ...located on the left side of the bottom of the housing The inlet fitting is near the front of the housing and the exhaust fitting is near the back of the housing The sample fittings accept 1 4 in rigid tubing See the Installation section on page 14 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 fa...

Page 9: ...mplifier and the CO amplifier to the main circuit board NOTE The LEL amplifier and CO amplifier are factory wired to the main circuit board See Installation on page 14 for all wiring procedures related to the sample draw detector Interconnect Terminal Strip The interconnect terminal strip is the lower twelve point terminal strip in the bottom right corner of the main circuit board Use the intercon...

Page 10: ...ou can see it through the window in the door A ball in the flowmeter column indicates the flow rate to the sensor The flowmeter measures the flow in the range 0 2 to 2 0 SCFH Standard Cubic Feet per Hour The optimum flow rate is 1 0 SCFH Sensor Flow Control Valve The sensor flow control valve is mounted to the flowmeter circuit board above the flowmeter The sensor flow control valve adjusts the fl...

Page 11: ...n circuit board behind the hydrophobic filter Its function is to isolate the carbon monoxide sensor from vibrations in the flow line that are caused by the pump Combustible Gas Sensor The catalytic combustible gas sensor detects combustible gas in the LEL range It uses a catalytic element for detection The reaction of gas with oxygen on the catalyst causes a change in the resistance of the element...

Page 12: ...e 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 dec...

Page 13: ...ector amp terminal strip Figure 4 CO Amplifier Component Location Zero Pot The zero pot is located in the lower right corner of the amplifier see Figure 4 Use a small flat blade screwdriver to turn the zero pot s adjustment screw and adjust the amplifier s zero output during the start up and calibration procedures Turn the adjustment screw clockwise to increase the zero output and counterclockwise...

Page 14: ...ct 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 5 Outline and Mounting Dimensions Ø 30 x 50 4X MOUNTING 78 1 13 40 Pilot Fail 85 80 4 50 NOTE Housing is4 3 inchesdeep 8 8...

Page 15: ... are visible 2 Push the particle filter s tubing stub into the inlet fitting until it stops Be sure the arrow on the particle filter is pointing toward the inlet fitting 3 Hand tighten the nut on the inlet fitting so the ferrules clamp on the tubing If the tube nut is removed see Figure 7 for the arrangement of the fitting components 4 Connect a length of sample tubing to the other side of the par...

Page 16: ...he incoming sample line To reduce response time keep the incoming sample line as short as possible 5 If desired install the particle filter onto the end of the inlet line Be sure the arrow on the particle filter is pointed toward the inlet line Installing the Exhaust Line 1 Loosen the nut on the exhaust fitting until 3 threads are visible 2 Push 1 4 O D rigid polypropylene or rigid Teflon sample t...

Page 17: ...ough the conduit hub at the bottom of the sample draw housing A minimum of 18 AWG wire is recommended 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 If using shielded cable leave the cable shield s drain wire insulated and disconnected at the sample draw detector You will conn...

Page 18: ...tor terminal strip connections specific to the controller Figure 6 Wiring the Sample Draw Detector to a Controller Black White Red Not Used on This Version ZE RO S PAN Red Blue S S PWR SIG Black LEL IR Red White LEL IR AMP 2 AMP 1 AMP 1 AMP 2 P A T S 2 0 1 P A T S 2 0 1 Green P A T S 1 0 1 P A T S 1 0 1 CO OXY OXY DC Ground Controller or Recording Device 4 20 Signal 24 VDC 4 20 Signal 24 VDC IR CH...

Page 19: ...entarily RKI controllers have a one minute warmup period when the controller does not display any gas reading or give any alarm indication The transmitter 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 valv...

Page 20: ... ppm for the CO channel start up is complete The sample draw detector is in normal operation If the display reading is not 0 LEL for the combustible gas channel or 0 ppm for the CO channel continue with step 3 3 Perform a zero fresh air operation at the controller See Calibration LEL Sensor on page 28 and Calibration CO Sensor on page 30 for instructions to perform a zero fresh air operation Maint...

Page 21: ...s flow rate is too low because of an obstructed sample line failed pump etc The sample draw detector is malfunctioning The sensor wiring is disconnected or misconnected Recommended action 1 At the sample draw detector set the correct flow rate with the sensor flow control valve 2 If you cannot set the correct flow rate check the sample lines for obstructions or kinks 3 Verify that the sensor wirin...

Page 22: ... 6 If the calibration response difficulties continue contact RKI Instruments Inc for further instruction Replacing Components of the Sample Draw Detector This section includes procedures to replace the LEL sensor LEL amplifier carbon monoxide sensor carbon monoxide amplifier hydrophobic filter and particle filter Replacing the Combustible Gas Sensor 1 Turn off the controller 2 Turn off power to th...

Page 23: ... careful not to lose any of these parts 6 Remove the old amplifier from 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 ...

Page 24: ...e bottom of the flow block Be sure the gasket stays in place 5 Unplug the sensor from the CO amplifier 6 Verify that you are using the correct replacement sensor then plug the sensor into the CO amplifier 7 Place the sensor and amplifier in the CO sensor cavity 8 Secure the CO amplifier on the flow block with the two screws you removed in step 4 9 Close and latch the housing door 10 Turn on power ...

Page 25: ... on the controller and place it into normal operation 13 Allow the sample draw detector to warmup for 5 minutes 14 Calibrate the sample draw detector as described in Calibration CO Sensor on page 30 Replacing the Hydrophobic Filter 1 Turn off the controller 2 Turn off power to the controller 3 Open the housing door of the sample draw detector 4 Disconnect the filter from the rubber elbows on each ...

Page 26: ... flow to 0 6 SCFH Turn the valve s knob clockwise to increase the flow and counterclockwise to decrease the flow If 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 swi...

Page 27: ...e 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 32 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 32 for the spare part numbers 4 Push the new tu...

Page 28: ...drogen Use the correct calibration gas for your installation NOTE This 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 reg...

Page 29: ...he Response Reading 1 Screw the regulator into the combustible gas 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 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 th...

Page 30: ...ing calibration mode 2 Screw the regulator into the zero air calibration cylinder 3 Open the housing door 4 Set a voltmeter to measure in the millivolt mV range 5 Connect the voltmeter to the test points on the CO amplifier Plug the positive lead into the red amplifier test point plug the negative lead into the black amplifier test point 6 Use the following formula to determine the correct test po...

Page 31: ...tector to draw the calibrating sample for 1 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 sample draw detector s inlet fitting 7 Reconnect the incoming ...

Page 32: ...02RK 03 Calibration cylinder 50 LEL hydrogen in air 103 liter 81 0007RK 01 Calibration cylinder 50 LEL hexane in air 34 liter steel 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 0064RK 01 Calibration cylinder 50 ppm CO in air 34 liter steel 81 0064RK 03 Calibration cylinder 50 ppm CO in air 103 liter 81 0...

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