RKI Instruments 35-3001-01H-DIL, Operator'S Manual

Page 1: ...www rkiinstruments com 35 3001 01H DIL Hydrogen Sample Draw Detector Operator s Manual Part Number 71 0381 Revision A Released 8 3 17 ...

Page 2: ...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 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 I...

Page 4: ...aw 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 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 Zero Reading 1...

Page 5: ...e dilution fitting Because of this it is important when calibrating the detector head to apply the calibration gas to the sample line inlet if a sample line is installed In addition because the detector head includes internal dilution it must be calibrated using a sample bag instead of a demand flow regulator See Calibration on page 18 for detailed calibration instructions Specifications Table 1 l...

Page 6: ...structions and warnings in this manual to assure proper and safe operation of the 35 3001 01H DIL and to minimize the risk of personal injury Be sure to maintain and periodically calibrate the 35 3001 01H DIL as described in this manual Accuracy 5 of reading or 2 LEL whichever is greater Table 1 Specifications ...

Page 7: ...ting W B G LEL Flow Block _ AMP 2 S OXY S AMP Sensor Flow Control Valve Fail LED Pilot LED Pressure Switch Adjustment Screw behind PCB Flowmeter W B G Interconnect Terminal Strip Pump Reset Switch OXY G W AMP 1 S S AMP 2 Hydrophobic Filter LEL IR R R Flowmeter Circuit Board Connector Pump Connector LEL IR 3 4 Conduit Hub Particle Filter Exhaust Fitting Inlet Fitting This End To Inlet Fitting Mount...

Page 8: ...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 end of t...

Page 9: ...connector is the two point connector below the oxygen terminal strip in the upper right 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 co...

Page 10: ...ates and water in the incoming gas sample from damaging the flow and detection systems Replace the filter when it appears dirty discolored or clogged Dilution Fitting The catalytic hydrogen sensor requires oxygen to operate In environments where there is not enough oxygen to operate the hydrogen sensor the dilution fitting adds sufficient oxygen by blending ambient air with the incoming sample The...

Page 11: ...t 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 3 Outline and Mounting Dimensions 2 Close and latch the housing door Ø 30 x 50 4X MOUNTING 78 1 13 40 Pilot Fail 85 80 4 50...

Page 12: ...e 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 size CAUTION If you use flexible sample tubing polyurethane is a...

Page 13: ...g 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 5 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 lengths based on tubing size Wiring the Sample...

Page 14: ...mple 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 White Green Black Red LEL IR P A T S 1 0 1 P A T S 1 0 1 P A T S 2 0 1 P A T S 2 0 1 LEL IR OXY OXY Black Green White Red AMP 1 AMP 1 AMP 2 Controller Detec...

Page 15: ...en end of the sample line with your thumb If the sensor flowmeter indication drops noticeably the instrument goes into a low flow alarm and the Fail LED turns on the incoming sample line is not leaking NOTE When the inlet line is plugged for this test the sensor flowmeter will not go to zero because the dilution fitting is allowing air to enter the sensor flow The pressure switch monitors the samp...

Page 16: ...low control valve to adjust the flow rate to 0 8 SCFH Turn the valve s knob clockwise to increase the flow and counterclockwise to decrease the flow 3 At the controller verify a display reading of 0 LEL 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 redu...

Page 17: ...bes 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 exhibits any problems Fail Condition Symptoms The sample draw detector s Fail LED is on The monitoring device is operating properly but indicates a reading...

Page 18: ...t the calibration cylinder contains an adequate supply of a fresh test sample 2 Use a different fixed 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 Check the dilution fitting for obstructions 6 If the calib...

Page 19: ...ow 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 0 8 SCFH then close the housing door Replacing the Particle Filter 1 Turn off the controller 2 Turn off power to the controller 3 If the particle filter is installed at the inlet fitting 1 Disconnect the tubing routed to the sampling area if installed fr...

Page 20: ...tor goes into low flow alarm before you can adjust the flow down to 1 0 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 1 0 SCFH NOTE The pressure switch adjustment screw is accessible through a circular cutout in the flowmeter circuit board 3 Slowly turn the pressure switch adjustment ...

Page 21: ...d come 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...

Page 22: ...the end of the inlet line not at the inlet fitting The calibration will not be accurate if calibration gas is applied at the inlet fitting 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 t...

Page 23: ...Clamp the gas bag shut and disconnect it from the fixed flow regulator 6 Connect the gas bag tubing to the inlet line and release the clamp 7 Allow the sample draw detector to draw sample for one minute 8 Follow the directions in the controller s operator s manual for setting the span 9 Disconnect the gas bag tubing from the inlet line 10 Empty the gas bag 11 Unscrew the fixed flow regulator from ...

Page 24: ...ttings 33 0165RK Hydrophobic filter 33 0167RK Particle filter 61 0155RK Hydrogen sensor plug in type LEL range 71 0381 Operator s Manual 35 3001 01H DIL Sample Draw Detector 81 0002RK 01 Calibration cylinder 50 LEL hydrogen in air 34 liter steel 81 0002RK 03 Calibration cylinder 50 LEL hydrogen in air 103 liter 81 0076RK 01 Zero air calibration cylinder 34 liter steel 81 0076RK 03 Zero air calibra...