35-3001-01-03
35-3001-01-03
Methane Sample-Draw Detector
Operator’s Manual
Part Number: 71-0301RK
Revision: 0
Released: 5/13/15
www.rkiinstruments.com
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.
Typical calibration frequencies for most applications are between
6 and 12 months, but can be required more often or less often
based on your usage.
35-3001-01-03 Methane Sample-Draw Detector
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. This warranty does not apply to those items which by their nature are subject
to deterioration or consumption in normal service, and which must be cleaned, repaired, or replaced
on a routine basis. Examples of such items are:
a) Absorbent cartridges
d) Batteries
b) Pump diaphragms and valves
e) Filter elements
c) Fuses
Warranty is voided by abuse including mechanical damage, alteration, rough handling, or repair
procedures not in accordance with the operator’s manual. This warranty indicates the full extent of
our liability, and we are not responsible for 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 PURPOSE. IN
NO EVENT SHALL RKI INSTRUMENTS, INC. BE LIABLE FOR INDIRECT,
INCIDENTAL, OR CONSEQUENTIAL LOSS OR DAMAGE OF ANY KIND
CONNECTED WITH THE USE OF ITS PRODUCTS OR FAILURE OF ITS
PRODUCTS TO FUNCTION OR OPERATE PROPERLY.
This warranty covers instruments and parts sold to users by authorized distributors, dealers, and
representatives as appointed by RKI Instruments, Inc.
We do not assume indemnification for any accident or damage caused by the operation of this gas
monitor, and our warranty is limited to the replacement of parts or our complete goods.
35-3001-01-03 Methane Sample-Draw Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
External Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting the Methane Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting the Sample Lines to the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring the Methane Sample-Draw Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing Components of the Methane Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
35-3001-01-03 Methane Sample-Draw Detector
Overview
This operator’s manual describes the 35-3001-01-03 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. See the controller Operator’s
Manual for information specific to the controller.
Table 1: Specifications
Target Gas and Detection Range
Methane (CH4): 0 - 100% volume
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.D. x 1/8” I.D. Tubing
Maximum Recommended Inlet/
Exhaust Line Length for
1/4” O.D. x 0.170” I.D. Tubing
Inlet
Exhaust
100 feet
0 feet
50 feet
50 feet
Inlet
Exhaust
100 feet
100 feet
Response Time
90% in 30 seconds
Accuracy
± 5% of reading or ± 2% of full scale (whichever is greater)
WARNING:
When using the 35-3001-01-03, you must follow the instructions and warnings in
this manual to assure proper and safe operation of the 35-3001-01-03 and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 35-3001-01-03 as described in this manual.
35-3001-01-03 Methane Sample-Draw Detector • 1
Description
This section describes the components of the methane sample-draw detector.
Pump Connector
Oxygen
Sensor
Terminal
Stri p
Mounting
Foot, 4X
Flowmeter Circuit
Board Connector
Sensor Flow
Control Valve
O
W X
+
Pump
Y
G
B
_ E
N
Fai l LED
Pilot LED
IR CH4
Sensor
(inside block)
IR CH4
Flow Block
Pump Reset
Switch
IR CH4
Sensor PCB
Flowmeter
Detector/Amp
Terminal Strip
(Factory Wired)
Pressure Switch
Adjustment Screw
(behind PCB)
+
S
+
+
S
AMP 2
AMP
Hydrophobic
Filter
S
AMP 1
+
S
AMP 2
R
+
OXY
W
G
+
OXY
W
G
B
LEL/ IR
R
W
G
B
LEL/ IR
Interconnect
Terminal
Stri p
Thi s End To
Inl et Fitting
3/4" Conduit Hub
Particle Filter
INLET
Inl et
Fitting
EXHAUST
Exhaust
Fitting
Figure 1: Methane Sample-Draw Detector Component Location
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
2 • 35-3001-01-03 Methane Sample-Draw Detector
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). Use the mounting
feet to install the housing to a vertical surface.
Sample Fittings
The sample fittings are 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 6 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 the inlet line, the tubing stub can be
used or removed.
Conduit Hub
One 3/4” conduit hub is located on the right side of the bottom of the housing. It is used for routing
wiring into the housing by using conduit or an appropriate cable bushing.
Internal Components
This section describes the sample-draw detector’s internal components (see Figure 1). Figure 2
illustrates how the gas sample moves through the flow system.
Pressure Switch
Exhaust
IR CH4
Sensor
Flowmeter PCB
Sensor
Flow
Control
Valve
Restrictor
Inlet
Flowmeter
Pump
Particle Filter
Hydrophobic Filter
Figure 2: Methane Sample-Draw Detector Flow Diagram
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).
35-3001-01-03 Methane Sample-Draw Detector • 3
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 methane sensor to the
main circuit board.
NOTE: The methane sensor is factory-wired to the main circuit board. See the “Installation”
section on page 6 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 interconnect terminal strip to connect the sample-draw detector to a
controller.
Oxygen Sensor Terminal Strip
The oxygen sensor terminal strip is a two-point terminal strip in the upper right corner of the main
circuit board. This terminal strip is not used in this version of the sample-draw detector.
Pump Connector
The pump 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 6 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 board connector to connect the flowmeter circuit
board to the main circuit board.
NOTE: The flowmeter circuit board is factory wired to the main circuit board. See “Installation”
on page 6 for all wiring procedures related to the sample-draw detector.
Flowmeter Circuit Board
The flowmeter circuit board is mounted to the left side of the main circuit board using standoffs. It
includes the flowmeter, sensor flow control valve, status LEDs, pressure switch, and pump reset
switch.
Flowmeter
The flowmeter is mounted to the right side of the flowmeter circuit board. You 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 flow rate to the detector. Turn the valve’s knob
counterclockwise to increase the flow and clockwise to decrease the flow.
4 • 35-3001-01-03 Methane Sample-Draw Detector
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. The pressure switch
monitors the flow rate of the incoming gas sample.
If the flow rate falls below the preset low flow level, the pressure switch causes the Fail LED to
turn on and interrupts the signal from the detector. The interrupted detector signal causes a fail
condition at the controller. The low flow level is factory-set at 0.6 SCFH (±0.1 SCFH). See
“Adjusting the Low Flow Setting” on page 14 to adjust this setting.
Pump Reset Switch
The pump reset switch is located to the left of the status LEDs. When a low flow condition 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 when it appears dirty, discolored, or clogged.
Pump
The pump is mounted to the right side of the main circuit board. The pump pulls the gas sample
into the sample-draw detector. The pump operates on 24 VAC, which is generated from the 24
VDC supplied by the controller.
IR Methane Sensor/IR Methane Sensor PCB
The methane sensor is an infrared type plug-in detector. Infrared combustible detectors are
generally used instead of the catalytic combustible detectors in applications where there may be
catalyst poisons such as silicone present or where oxygen is not present in the monitoring
environment.
The methane sensor is installed in the IR methane flow block and the IR methane flow block is
mounted to the middle of the main circuit board. A small circuit board, the IR methane sensor PCB,
with a 4-wire cable mates to the IR methane sensor and retains it in the flow block. The cable is
wired to the main PCB. The IR methane sensor PCB allows you to replace the sensor without
disconnecting the wiring.
35-3001-01-03 Methane Sample-Draw Detector • 5
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.
•
Are the flowmeter and status LEDs visible?
6.50
Ø .30 x .50 (4X) M OUNTING
1.13
.40
4.00
.78
Pilot
Fail
Sample Drawing
Gas Detector
8.50
35-3001
www.rkiinstruments.com
.80
.85
4.50
NOTE: Housing is 4.3 inches deep
Figure 3: Outline and Mounting Dimensions
6 • 35-3001-01-03 Methane Sample-Draw Detector
8.88
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.
Position the sample-draw housing on a vertical surface at eye level (4 1/2 to 5 feet from the
floor).
7.
Insert 1/4 inch screws through the slots in the mounting feet to secure the housing to the
mounting surface.
Connecting the Sample Lines to the Sample-Draw Detector
See Figure 5 for the fitting layout.
Installing the Inlet Line with Particle Filter Connected to the Inlet Fitting
1.
Loosen the nut on the inlet fitting until 3 threads 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 5 for the arrangement of the fitting 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 size.
CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate
insert if necessary to provide support to the tubing and ensure a good seal when
connecting to the flexible stub on the filter.
CAUTION: Avoid loops or slumps in the incoming sample line. To reduce response time, keep the
incoming sample line as short as possible.
Installing the Inlet Line without Particle Filter Connected to the Inlet Fitting
1.
Loosen the nut on the inlet 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.
CAUTION:
If you use flexible sample tubing (polyurethane is acceptable), use an appropriate
insert to seal the connection between the tubing and the inlet fitting.
35-3001-01-03 Methane Sample-Draw Detector • 7
3.
Hand tighten the nut on the inlet 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 tubing from the inlet fitting to the sample area. See “Specifications” on page 1 for
maximum tubing lengths based on tubing size.
CAUTION: Avoid loops or slumps in the 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 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.
CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate
insert 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 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 Methane Sample-Draw Detector to a Controller
WARNING:
Always verify that the controller is off and that power to the controller is off
before you make wiring connections.
1.
Turn off the controller.
2.
Turn off power to the controller.
3.
Unlatch and open the housing door of the sample-draw detector.
4.
Guide a six-conductor, shielded cable or six wires in conduit through 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
4.
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 connect the opposite end of the
drain wire at the controller.
7.
Route the cable or wires in conduit leading from the sample-draw detector through one of the
conduit hubs at the controller.
8 • 35-3001-01-03 Methane Sample-Draw Detector
8.
Connect the wires to the applicable detector/transmitter terminal strip at the controller as
shown in Figure 4. Refer to the controller operator’s manual and the controller detector head
specification sheet for the 35-3001-01-03 for detector/terminal strip connections specific to the
controller.
Not U sed on
This V ersion
B lack
Green
W hite
Red
To I R CH4
Sensor
AMP 2
AMP 1
AMP 2
OXY
LEL/IR
1
0
2
S
T
A
P
AMP 1
0
1
S
T
A
P
Controller D etector/
Transm itter T erm inal
Strip T erminals
OXY
LEL/IR
+ 24 V DC
- (DC G round)
Controller D etector/
Transm itter T erm inal
Strip, LE L D etector
Term inals
Red
W hite
Green
B lack
Figure 4: Wiring the Sample-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.
35-3001-01-03 Methane Sample-Draw Detector • 9
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.
5.
Verify that the controller is on and operating properly. Refer to the controller operator’s
manual.
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 counterclockwise to
increase the flow and clockwise to decrease the flow.
NOTE: The following step tests for leaks in the sample line. This test will cause a low flow
condition at the sample-draw detector and a fail condition at the controller. Be sure to put
the controller into its calibration program or disable external alarms before performing
this test.
7.
Verify that the incoming sample line is not leaking. To test the sample line, press and hold the
reset switch and plug the open end of the sample line with your thumb. If the flowmeter ball
drops to the bottom of the flowmeter, the incoming sample line is not leaking.
8.
Remove your thumb from the sample line, release the reset switch, and verify the flowmeter
returns to a normal flow rate.
9.
Enable alarms or place the controller in normal operation.
CAUTION: Allow the sample-draw detector to warm up for 5 minutes before you continue with
the next section, “Setting the Zero Reading.”
Setting the Zero Reading
CAUTION: If you suspect the presence of combustible gas in the monitoring environment, use
the calibration kit and the zero air calibration cylinder to introduce “fresh air” to
the sensor and verify an accurate zero setting. See “Calibration” on page 16 for
instructions on using a zero air calibration cylinder for setting the zero reading.
1.
Verify that the sample-draw detector is sampling a fresh air environment (environment known
to be free of combustible gas).
2.
Verify a reading of 0 %vol on the controller display screen for the applicable channel.
If the display reading is 0 %vol, start up is complete. The sample-draw detector is in normal
operation. If the display reading is not 0 %vol, continue with step 3.
3.
Perform a zero operation at the controller. See “Setting the Zero Reading” on page 16 and the
controller operator’s manual for instructions to perform a zero operation.
10 • 35-3001-01-03 Methane Sample-Draw Detector
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, 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, monthly, and biannual procedures.
Daily Visual Checks
1.
Verify that the Pilot LED is on.
2.
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 to 1.0 SCFH. Turn the valve’s knob
counterclockwise to increase the flow and clockwise to decrease the flow.
3.
Verify a display reading of 0 %vol at the controller. 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 reduce the response time of this test, use a short incoming sample line. If the sampledraw detector’s sample line is long, connect a shorter line for this test. Make sure you
reconnect the sample line after you complete this procedure.
NOTE: Performing a response test on the sample-draw detector may cause alarms. Be sure to put
the controller into its calibration program or disable external alarms before performing
this test.
Preparing for the response test
NOTE: This procedure describes the RKI calibration kit that includes a demand flow regulator.
1.
Verify that the display reading at the controller is 0 %vol.
If the display reading is not 0 %vol, set the zero reading as described in “Calibration” on
page 16, then continue this procedure.
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.
After approximately one minute, verify that the reading at the controller stabilizes within ±
20% of the concentration of the test sample. If the reading is not within ± 20% of the test
sample, calibrate the sample-draw detector as described in “Calibration” on page 16.
4.
Remove the calibration tubing from the inlet fitting, then reconnect the sample tubing to the
inlet fitting.
35-3001-01-03 Methane Sample-Draw Detector • 11
5.
Store the calibration kit in a safe place.
Biannual Calibration
Calibrate the sample-draw detector as described in “Calibration” on page 16.
Troubleshooting
The troubleshooting guide describes 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 well below zero.
Probable causes
•
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.
•
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 wiring is correct and secure. “Wiring the Methane Sample-Draw
Detector to a Controller” on page 8 describes sensor wiring connections.
4.
Calibrate the sample-draw detector as described in “Calibration” on page 16.
5.
If the fail condition continues, replace the sensor as described in “Replacing the Infrared
Methane Sensor” on page 13.
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.
•
Unable to accurately set the zero or response reading during the calibration 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.
12 • 35-3001-01-03 Methane Sample-Draw Detector
Recommended action
1.
Verify that the calibration cylinder contains an adequate supply of a fresh test sample.
2.
If a demand flow regulator calibration kit is used, use a different demand 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.
If the calibration/response difficulties continue, replace the sensor as described later in this
section.
6.
If the calibration/response difficulties continue, contact RKI Instruments, Inc. for further
instruction.
Replacing Components of the Methane Sample-Draw Detector
This section includes procedures to replace the sensor, hydrophobic filter, and particle filter.
Replacing the Infrared Methane Sensor
1.
Turn off the controller.
2.
Turn off power to the controller.
3.
Open the housing door of the sample-draw detector.
4.
Unscrew and remove the four screws that secure the IR methane sensor PCB, then lift the IR
methane sensor PCB and sensor off of the flow block.
There is a gasket at the bottom of the flow block. Be sure the gasket stays in place.
5.
Unplug the sensor from the IR methane sensor PCB.
6.
Verify that you are using the correct replacement sensor, then plug the sensor into the IR
methane sensor PCB.
7.
Place the sensor and sensor PCB in the methane sensor cavity.
8.
Secure the sensor PCB on the flow block with the four screws you removed in step 4.
9.
Close and latch the housing door.
10. Turn on power to the controller.
11. Turn on the controller.
CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue.
12. Calibrate the replacement sensor as described in “Calibration” on page 16.
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 end of the filter, then remove the filter
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.
35-3001-01-03 Methane Sample-Draw Detector • 13
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.
If the particle filter is installed at the inlet fitting:
4.
1.
Disconnect the tubing routed to the sampling area, if installed, from the particle filter.
2.
Disconnect the particle filter from the tubing stub.
3.
Install the new particle filter onto the tubing stub. Be sure the arrow on the particle filter is
pointing toward the inlet fitting.
4.
Reinstall the tubing routed to the sampling area.
If the particle filter is installed at the end of the inlet line:
1.
Remove the particle filter from the tubing stub.
2.
Install the new particle filter onto the tubing stub. Be sure the arrow on the particle filter is
pointing toward the inlet line.
5.
Turn on power to the controller.
6.
Turn on the controller.
Adjusting the Low Flow Setting
NOTE: Adjusting the low flow setting will cause a low flow alarm at the sample-draw detector
and a fail alarm at the controller. Be sure to put the controller into its calibration program
or disable external alarms before performing this test.
The factory-set low flow setting is 0.6 SCFH (±0.1). To adjust the low flow setting:
1.
Use the sensor flow control valve to set the flow to 0.6 SCFH. Turn the valve’s knob
counterclockwise to increase the flow and clockwise 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 switch adjustment screw is accessible through a circular cutout in the
flowmeter circuit board.
2.
Slowly turn the pressure switch adjustment screw counterclockwise just until the sample-draw
detector goes into low flow alarm.
3.
Turn the sensor flow control valve’s knob counterclockwise to increase the flow until the unit
is out of low flow alarm when the reset button is pressed and released.
4.
Decrease the flow very slowly by turning the sensor flow control valve’s knob clockwise and
verify that the low flow alarm is 0.6 SCFH (±0.1).
If the low flow alarm is set too high, turn the pressure switch adjustment screw slightly
clockwise. Repeat steps 3 and 4 if necessary.
5.
Use the sensor flow control valve to set the flow to 1.0 SCFH.
6.
Make sure the sample-draw detector’s Fail LED is off.
14 • 35-3001-01-03 Methane Sample-Draw Detector
Removing the Particle Filter’s Tubing Stub, if Necessary
A short tubing stub comes factory installed in the particle filter. It is used for connecting the particle
filter to the inlet fitting. If you have installed the particle filter and no longer want it installed, you
will need to remove the particle filter’s tubing stub from the inlet fitting and replace it with tubing.
1/4" Tube
Inside of Case
Outside of Case
O-ring
Fitting Body
Back Ferrule
Tube Nut
Front Ferrule
1/4" Tube
Figure 5: Inlet Fitting with Tubing Stub
CAUTION: Do not pull the tubing stub downward to remove it.
1.
Remove the particle filter from its tubing stub.
2.
Unscrew the outside inlet fitting tube nut from the fitting body. The tubing stub should come
out with the tube nut. Be careful not to lose the O-ring that may come out with the tubing stub.
3.
Push the tubing stub up and out of the front ferrule being careful not to lose the ferrule set.
4.
Push the new tubing up through the inlet fitting tube nut and replace the ferrule set and the Oring, if it came out, in the orientation shown in Figure 5.
5.
Screw the inlet fitting tube nut back onto the fitting body. See “Connecting the Sample Lines to
the Sample-Draw Detector” on page 7 for instructions to install a new piece of tubing into the
fitting.
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 transmitter applications.
Unless experience in a particular application dictates otherwise, RKI Instruments, Inc. recommends
a calibration frequency of every 6 months.
If an application is not very demanding, for example detection in a clean, temperature controlled
environment where calibration adjustments are minimal at calibration, then a calibration frequency
35-3001-01-03 Methane Sample-Draw Detector • 15
of every 9 to 12 months is adequate.
If an application is very demanding, for example if the environment is not well controlled, then
more frequent calibration than every 6 months may be necessary.
Calibration
This section describes how to calibrate the methane sample-draw detector. It includes procedures to
prepare for calibration, set the zero reading, set the response reading, and return to normal
operation.
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 regulator into a zero air calibration cylinder.
Setting the Zero Reading
1.
Connect the sample tubing from the demand flow regulator to the sample-draw detector’s inlet
line. This step is not necessary if you verified a fresh air environment earlier in this
procedure.
2.
Allow the sample-draw detector to draw sample for one minute.
3.
Follow the directions in the controller’s operator’s manual for setting the zero reading. If you
used a zero air calibration cylinder to set the zero reading, proceed to step 4. If you verified a
fresh air environment, proceed to the next section, Setting the Response Reading.
4.
Disconnect the sample tubing from the inlet line.
5.
Unscrew the regulator from the zero air calibration cylinder.
Setting the Response Reading
1.
Screw the regulator into the methane 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.
Follow the directions in the controller’s operator’s manual for setting the span.
5.
Disconnect the sample tubing from the inlet line.
6.
Unscrew the regulator from the methane calibration cylinder.
Returning to Normal Operation
1.
Wait approximately one minute to allow the methane reading to stabilize.
2.
Follow the instructions in the controller’s operator’s manual to exit the calibration mode.
3.
Store the components of the calibration kit in a safe and convenient place.
16 • 35-3001-01-03 Methane Sample-Draw Detector
Parts List
Table 2 lists replacement parts and accessories for the methane sample-draw detector.
Table 2: Parts List
Part Number
Description
06-1248RK
Sample tubing, 3/16 x 5/16, specify length
06-1248RK-03
Sample tubing, 3/16 x 5/16, 3 feet (for calibration kit)
07-0110RK
Gasket for IR flow block
30-1016RK
Pump
33-0165RK
Hydrophobic filter
33-0167RK
Particle filter
61-5041RK-CH4
Infrared methane sensor, plug-in type, %vol range
71-0301RK
Operator’s Manual, 35-3001-01-03 Sample-Draw Detector
81-0013RK-01
Calibration cylinder, 50% vol methane in nitrogen, 34 liter steel
81-0013RK-05
Calibration cylinder, 50% vol methane in nitrogen, 58 liter steel
81-0076RK-01
Zero air calibration cylinder (34 liter)
81-0076RK-03
Zero air calibration cylinder (103 liter)
81-1054RK
Regulator, demand flow, for 58- and 103-liter cylinders
81-1055RK
Regulator, demand flow, for 17- and 34-liter steel cylinders
35-3001-01-03 Methane Sample-Draw Detector • 17
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