35-3001A-01-01 Methane Sample-Draw Detector Operator’s Manual Part Number: 71-0310RK Revision: P4 Released: 9/17/14 www.rkiinstruments.
WARNING Read and understand this instruction manual before operating detector. Improper use of the detector could result in bodily harm 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.
Product Warranty RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free from defects in materials, workmanship, and performance for a period of one year from date of shipment from RKI Instruments, Inc. Any parts found defective within that period will be repaired or replaced, at our option, free of charge.
Table of Contents Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 External Components. . . . . . . . . . . . . . . .
Overview This operator’s manual describes the 35-3001A-01-01 methane sample-draw detector. This manual also describes how to install, start up, maintain, and calibrate the sample-draw detector when using it with a gas monitoring controller. A parts list at the end of this manual lists replacement parts and accessories for the sample-draw detector. Specifications Table 1 lists specifications for the methane sample-draw detector.
Description This section describes the components of the methane sample-draw detector.
External Components This section describes the sample-draw detector’s external components. Housing The sample-draw detector’s fiberglass housing is weather- and corrosion-resistant. It is suitable for installation where general purpose equipment is in use. The housing door is hinged on the left side and is secured by two latches on the right side. The flowmeter and status LEDs are visible through a window in the housing door. Four mounting feet are attached to the back of the housing (one at each corner).
Main Circuit Board The main circuit board includes the detector/amp terminal strip, interconnect terminal strip, oxygen sensor terminal strip, pump connector, and flowmeter circuit board connector (see Figure 1). Detector/Amp Terminal Strip The detector/amp terminal strip is the upper twelve-point terminal strip in the bottom right corner of the main circuit board. Use the detector/amp terminal strip to connect the amplifier to the main circuit board.
counterclockwise to increase the flow and clockwise to decrease the flow. Status LEDs Two status LEDs are above the flowmeter. They are also visible through the window in the housing door. The green Pilot LED is on when the sample-draw detector is receiving power from the controller. The red Fail LED is on when the sample flow rate is below the low flow level. Pressure Switch The pressure switch is mounted to the back of the flowmeter circuit board.
Span Pot The span pot is located below the zero pot (see Figure 1). 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.
Installation This section describes procedures to mount the sample-draw detector in the monitoring environment and wire the sample-draw detector to a controller. Mounting the Methane Sample-Draw Detector 1. Select the mounting site. Consider the following 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.
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 the mounting foot to the housing, then rotate the mounting foot 180 degrees (see Figure 3). 4. Tighten the screw that secures the mounting foot to the housing. 5. Repeat steps 3 and 4 for the remaining three mounting feet. 6.
ring, if it came out, in the orientation shown in Figure 4. 4. Screw the inlet fitting tube nut back onto the fitting body. See the next section for instructions to install a new piece of tubing into the fitting. Connecting the Sample Lines to the Sample-Draw Detector See Figure 4 for the fitting layout. Installing the Inlet Line with Particle Filter 1. Connect the particle filter to the tubing stub on the inlet by pushing the flexible tubing on the filter onto the stub.
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 tubing into the fitting until it stops. Flexible polyurethane tubing may be used with an appropriate insert. 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.
8. Connect the wires to the applicable detector/transmitter terminal strip at the controller as shown in Figure 5. Refer to the controller operator’s manual and the controller detector head specification sheet for the 35-3001A-01-01 for detector/terminal strip connections specific to the controller.
Start Up This section describes procedures to start up the sample-draw detector and place the sample-draw detector into normal operation. Introducing Incoming Power 1. Complete the installation procedures described earlier in this manual. 2. Verify that the wiring is correct and secure. Refer to the controller operator’s manual for connections at the controller. 3. Turn on or plug in the power to the controller, then turn on the controller. 4. Verify that the sample-draw detector’s Pilot LED is on.
6. If necessary, use a small flat-blade screwdriver to adjust the zero potentiometer until the voltmeter reading is 100 mV (± 2 mV). 7. Remove the voltmeter leads from the test points. 8. Close the housing door. Maintenance This section describes maintenance procedures. It includes preventive maintenance procedures. This section also includes procedures to troubleshoot the sample-draw detector, replace components of the sample-draw detector, and adjust the low flow setting.
4. Use the following formula to determine the correct test points output for the test sample. Output (mV) = (calibrating sample/fullscale) X 400 + 100 For example, with a test sample of 50 %LEL and a fullscale setting of 100 %LEL, the correct output is 300 mV. 300 (mV) = (50/100) X 400 +100 Performing the response test 1. Screw the demand flow regulator into the calibration cylinder. 2. Connect the calibration tubing from the demand flow regulator to the inlet fitting. Gas will begin to flow. 3.
4. Calibrate the sample-draw detector as described in “Calibration” on page 18. 5. If the fail condition continues, replace the sensor as described in “Replacing the Infrared Methane Sensor” on page 15. 6. If the fail condition continues, contact RKI Instruments, Inc. for further instruction. Slow or No Response/Difficult or Unable to Calibrate Symptoms • The sensor responds slowly or does not respond during the monthly response test.
9. Turn on power to the controller and place it into normal operation. 10. Turn on the controller. CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue. 11. Calibrate the replacement sensor as described in “Calibration” on page 18. Replacing the Amplifier 1. Turn off the controller. 2. Turn off power to the controller. 3. Open the housing door of the sample-draw detector. 4.
10. Turn on power to the controller. 11. Turn on the controller and place it into normal operation. 12. Allow the sample-draw detector to warmup for 5 minutes. 13. Calibrate the sample-draw detector as described in “Calibration” on page 18 of this manual. Replacing the Hydrophobic Filter 1. Open the housing door of the sample-draw detector. 2. Disconnect the filter from the rubber elbows on each end of the filter, then remove the filter from the sample-draw detector. 3. Install the new filter.
Calibration Frequency Although there is no particular calibration frequency that is correct for all applications, a calibration frequency of every 6 months is adequate for most infrared combustible gas sample draw applications. Unless experience in a particular application dictates otherwise, RKI Instruments, Inc. recommends a calibration frequency of every 6 months.
voltmeter reading is 100 mV (± 2 mV). If you used a zero air calibration cylinder to set the zero reading, proceed to step 5. If you verified a fresh air environment, proceed to the next 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.
Parts List Table 2 lists replacement parts and accessories for the methane sample-draw detector. Table 4: Parts List Part Number Description 06-1248RK Sample tubing, 3/16 in. x 5/16 in., specify length 06-1248RK-03 Sample tubing, 3/16 in. x 5/16 in.
