RKI Instruments 35-3010RK-01, Manual

Page 1: ...rkiinstruments com 35 3010RK 01 Sample Draw Detector Part Number 71 0135RK Revision C Released 9 24 13 ...

Page 2: ...ic 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: ...cement 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 NO E...

Page 4: ... Flow Alarm 13 Maintenance 13 Preventive Maintenance 13 Troubleshooting 14 Replacing Components of the Sample Draw Detector 16 Adjusting the Low Flow Setting 18 Calibration Frequency 18 Calibration LEL Detector 18 Setting the Zero Reading 18 Setting the Response Reading 19 Returning to Normal Operation 19 Calibration Oxygen Detector 20 Setting the Zero Reading 20 Setting the Fresh Air Reading 20 R...

Page 5: ...sonal injury Be sure to maintain and periodically calibrate the 35 3010RK 01 as described in this manual Table 1 Specifications Target Gases Detection Ranges Combustible Gas 0 100 LEL Oxygen 0 25 volume Hydrogen Sulfide H2S 0 100 ppm Carbon Monoxide CO 0 300 ppm Input Power 24 VDC Current Draw 275 mA Output Signals 4 20 mA each channel Construction housing Fiberglass polyester NEMA 4X Dimensions 1...

Page 6: ...ured 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 the interior of the housing The sample draw detector s internal components are mounted to the subpane...

Page 7: ...as sample to enter the sample draw detector The INLET fitting accepts 1 4 in rigid tubing See Installation on page 8 for instructions to connect tubing 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 di...

Page 8: ...ill 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 sensors 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 3 Status Lights...

Page 9: ...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 f...

Page 10: ... main circuit board the one on the left is for the CO sensor signal and the one of the right is for the H2S sensor signal Main Circuit Board Figure 3 Main Circuit Board The main circuit board includes the interconnect terminal strip sensor transmitter terminal strip amp 1 circuit amp 2 circuit pump terminal strip relay and reset switch NOTE The flowmeter and status lights are mounted to the main c...

Page 11: ... pot to make adjustments to the zero reading The test points are labeled CAL 1 and CAL 1 for the CO channel and CAL 2 and CAL 2 for the H2S channel A 100 mV 500 mV output is available at each set of test points for use during calibration Pump Terminal Strip The pump terminal strip is the four point terminal in the top left corner of the circuit board Use the pump terminal strip to connect the pump...

Page 12: ...onnections at the right of the housing Make sure there is sufficient room to perform start up maintenance and calibration procedures Figure 4 Mounting the Sample Draw Detector 2 Close and latch the housing door NOTE The sample draw detector is shipped with the mounting feet tucked under the housing to protect the mounting feet during shipment 3 Slightly loosen the screw that secures one of the mou...

Page 13: ...source is OFF before you make wiring connections 1 Turn off the controller 2 Turn off or unplug power to the controller 3 Unlatch and open the housing door of the sample draw detector 4 Guide an eleven conductor 18 gauge shielded cable or eleven 18 gauge wires in conduit through one of the conduit hubs at the bottom of the sample draw housing If necessary use both hubs to bring the wires in making...

Page 14: ...stud that can be used to ground the cable s drain wire Figure 5 External Field Wiring Sample Draw Detector H2S Controller Transmitter Terminals Interconnect Terminal Strip 24 VDC 24 VDC Controller LEL Terminals Controller Oxygen Terminals CO Controller Transmitter Terminals S 4 20 mA 24 VDC R B G W G W S 4 20 mA Main Circuit Board Sample Draw Housing ...

Page 15: ...e 6 Internal Factory Wiring Sample Draw Detector Oxygen Sensor Green White White Green Black Pump Factory Wired CO CO H2S Sensors Plug Into Far Side of Preamp Circuit Board Pressure Switch Factory Wired LEL Detector LEL Sensor Connector H2S Red ...

Page 16: ...mb from the sample line press the pump reset switch and verify the flowmeter returns to a normal flow rate Setting the Zero Reading CAUTION If you suspect the presence of combustible gas carbon monoxide hydrogen sulfide or an abnormal oxygen condition not 20 9 in the monitoring environment use the calibration kit and the zero air calibration cylinder to introduce fresh air to the sample draw adapt...

Page 17: ...lowrate falls below 0 6 SCFH 0 2 SCFH then the sample draw detector will initiate a low flow alarm In a low flow alarm the Fail LED will turn on and the pump will shut off In addition the sensor signals to the controller will be interrupted by the sample draw detector resulting in a failure indication for each channel at the controller If a low flow alarm occurs press the pump reset switch for abo...

Page 18: ...ration section Use of a 4 gas cylinder is recommended so that all channels may be checked at once Performing the response test NOTE This procedure describes the RKI calibration kit that includes a demand flow regulator 1 Screw the regulator into the calibration cylinder 2 Connect the calibration tubing from the regulator to the inlet line at or near the INLET fitting Gas will begin to flow 3 After...

Page 19: ...rom the problem channel or channels as described later in this section 6 If the fail condition continues contact RKI Instruments Inc for further instruction Slow or No Response Difficult or Unable to Calibrate Symptoms One or more of the sensors respond slowly or does not respond during the monthly response test Unable to accurately set the zero or response reading on one or more of the channels d...

Page 20: ...in step 3 8 Turn on incoming power 9 Calibrate the replacement sensor as described in Calibration LEL Detector on page 18 Replacing the Oxygen Sensor 1 Turn off incoming power 2 Open the housing door of the sample draw detector 3 Unscrew and remove the two screws that secure the retaining plate then lift the plate connector and sensor out of the housing 4 Unplug the connector from the socket that ...

Page 21: ... of the preamp circuit board 6 Plug the new sensor into the preamp board 7 Reinstall the preamp circuit board with the sensors onto the flow block 8 Turn on incoming power 9 Calibrate the replacement sensor as described in Calibration H2S and CO Detectors on page 21 Replacing the Hydrophobic Filter 1 Turn off or unplug power to the controller 2 Locate the hydrophobic filter It is just to the left ...

Page 22: ...ns a calibration frequency of every 3 months is adequate for most sample draw detector applications Unless experience in a particular application dictates otherwise RKI Instruments Inc recommends a calibration frequency of every 3 months for the sample draw detector If an application is not very demanding for example detection in a clean temperature controlled environment and calibration adjustmen...

Page 23: ... calibration cylinder 2 Connect the sample tubing to the regulator 3 Follow the directions in the controller s operator s manual for setting the response reading for the LEL channel 4 When the instructions call for applying gas to the detector connect the sample tubing from the regulator to the inlet line at or near the INLET fitting 5 Allow the calibration gas to flow for 1 minute 6 Set the respo...

Page 24: ...for setting the zero reading for the oxygen channel 4 When the instructions call for applying gas to the detector connect the sample tubing from the regulator to the inlet line at or near the INLET fitting 5 Allow the gas to flow for one minute 6 Set the zero reading according to the controller operator s manual 7 Disconnect the sample tubing from the inlet line 8 Unscrew the regulator from the 4 ...

Page 25: ...he housing door 2 Set a voltmeter to measure in the millivolt mV range It will be used in the calibration of the CO and H2S channels When checking the mV output of the CO channel plug the voltmeter leads into the test points in the AMP 1 section of the main circuit board Plug the positive lead into the test point labeled CAL 1 plug the negative lead into the test point labeled CAL 1 When checking ...

Page 26: ...minute 4 Check the mV output on the AMP 1 test points for CO and verify that the reading matches the response reading 2 mV you determined earlier 5 If necessary use the AMP 1 span pot to adjust the reading to match the correct response reading 6 Check the mV output on the AMP 2 test points for H2S and verify that the reading matches the response reading 2 mV you determined earlier 7 If necessary u...

Page 27: ...RK Sealing gasket for CO and H2S flow block cavities 30 0610RK Pump 33 0171RK Hydrophobic filter AcroPak 33 6095RK Charcoal filter CF 188 65 0601RK Oxygen sensor 81 0076RK 01 Zero air calibration cylinder 34 liter 81 0154RK 04 4 gas calibration gas cylinder 50 LEL methane 12 oxygen 50 ppm CO 25 ppm H2S 34 liters 81 0155RK Regulator demand flow for 17 and 34 liter steel cylinders ES 1531 CO CO sens...