35-3001-07-01 Methane/Hydrogen Sulfide Sample-Draw Detector Operator's Manual
35-3001-07-01 Methane/Hydrogen Sulfide Sample-Draw Detector Operator's Manual
35-3001-07-01 Methane/Hydrogen Sulfide Sample-Draw Detector Operator's Manual
Methane/Hydrogen Sulfide
Sample-Draw Detector
Operator’s Manual
www.rkiinstruments.com
WARNING
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.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
External Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting the Sample Lines to the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring the Sample-Draw 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calibration, IR CH4 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specifications
Table 1 lists specifications for the methane/hydrogen sulfide sample-draw detector. See the
controller Operator’s Manual for information specific to the controller.
Table 1: Specifications
75 feet 0 feet
Accuracy Methane:
± 5% of reading or ± 2% of full scale (whichever is greater)
Hydrogen Sulfide:
± 5% of reading or ± 2 ppm H2S (whichever is greater)
WARNING: When using the 35-3001-07-01, you must follow the instructions and warnings in
this manual to assure proper and safe operation of the 35-3001-07-01 and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 35-3001-07-01 as described in this manual.
Sensor Flow O
W X
Control V alve
+
Y
G Pump
B E
_
N
Fail LED
H2S S ensor
Pilot LED (inside b lock)
H2S
Amplifier
H2S F low
Block
Pump Reset
Switch IR CH4 Sensor
(inside b lock)
IR CH4
Flow Block
Flowmeter
IR CH4
Sensor P CB
Pressure Switc h Flow Baffle
Adjustment Screw
(behind P CB) + S + S + R W G B Detec tor/Amp
AMP AMP 2 OXY LEL/ IR Terminal Strip
Hydrophobic (Factory W ired)
Filter
+ S + S W G R W G B
+
AMP 1 AMP 2 OXY LEL/ IR
Interc onnect
This End To Terminal
Inlet Fitting Strip
INLET
Inlet
Fitting EXHAUST
Exhaust
Fitting
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
Hydrogen
Flowmeter PCB
Sulfide
Restrictor Sensor
Sensor Flow
Control Valve
Inlet Flow
Baffle
IR CH4
Sensor
Particle Filter Pump
Hydrophobic Filter
NOTE: The IR CH4 sensor and H2S amplifier are factory-wired to the main circuit board. See the
“Installation” section on page 7 for all wiring procedures related to the sample-draw
detector.
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.
NOTE: The flowmeter circuit board is factory wired to the main circuit board. See “Installation”
on page 7 for all wiring procedures related to the sample-draw detector.
Test Points
100-500 mV Range
Zero Pot
Span Pot
Figure 3: H2S Amplifier Component Location
Zero Pot
The zero pot is located in the lower right corner of the amplifier (see Figure 3). 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 to decrease the zero output.
Span Pot
The span pot is located to the left of 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 during the
calibration procedure. Turn the adjustment screw clockwise to increase the span output and
counterclockwise to decrease the span output.
Test Points
The test points are on the top edge of the amplifier (see Figure 3). The test points produce a 100 mV
to 500 mV output that corresponds to the sample-draw detector’s 4 to 20 mA output. Use the test
points and a voltmeter to measure the amplifier’s output during the start-up and calibration
procedures. The black test point (CAL 2) in the upper left corner is the negative (-) test point and
the red test point (CAL 1) in the upper right corner is the positive (+) test point.
.40 4.00
.78
Pilot Fail
Sample Drawing
Gas Detector
www.rkiinstruments.com
.80
.85
4.50
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 4).
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 6 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 6 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.
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 6 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-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.
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.
Not Used i n
This V ersion
Blue (S)
Red (+)
Black
Green
W hite
Red
IR CH4
AM P 1 AM P 2 OX Y LEL/IR Sensor P CB
1
0
2
S
T
A
P
0
1
S
T
A
P
AM P 1 AM P 2 LEL/IR
IR CH4
OX Y
Sensor
+ 24 V DC
H2S 4/20 Signal
- (DC Ground)
Red
W hite
IR CH4
Green
Black
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.
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.”
CAUTION: If you suspect the presence of combustible or toxic gas or an abnormal oxygen
concentration 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, IR CH4 Sensor” on page 19 and “Calibration, H2S
Sensor” on page 20 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 and toxic gas and of normal oxygen concentration, 20.9%).
2. Verify a reading of 0 %LEL for the methane channel and 0 ppm for the H2S channel on the
controller display screen for the applicable channel.
If the display reading is 0 %LEL for the methane channel and 0 ppm for the H2S channel, start
up is complete. The sample-draw detector is in normal operation. If the display reading is not
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 quarterly 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 clockwise
to increase the flow and counterclockwise to decrease the flow.
3. Verify a display reading of 0 %LEL for the combustible channel and 0 ppm for the hydrogen
sulfide channel 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 sample-
draw 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.
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 %LEL for the methane channel and 0 ppm
for the hydrogen sulfide channel.
If the display reading is not 0 %LEL for the methane channel or 0 ppm for the hydrogen
sulfide channel, set the zero reading as described in “Calibration, IR CH4 Sensor” on page 19
or “Calibration, H2S Sensor” on page 20, then continue this procedure.
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.
CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue.
12. Calibrate the replacement sensor as described in “Calibration, IR CH4 Sensor” on page 19.
Replacing the H2S 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 the two screws in the upper right and lower left corners of the H2S flow block then
lift the H2S amplifier 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 H2S amplifier.
6. Verify that you are using the correct replacement sensor, then plug the sensor into the H2S
amplifier.
7. Place the sensor and amplifier in the H2S sensor cavity.
8. Secure the H2S 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 to the controller.
11. Turn on the controller.
12. Allow the sample-draw detector to warmup for 5 minutes.
13. Calibrate the replacement sensor as described in “Calibration, H2S Sensor” on page 20.
NOTE: When the sample-draw detector is first powered up with a new amplifier, the initial
output may be either high or below zero depending on the setting of the span pot. Be sure
to make arrangements so that this does not cause unwanted alarms.
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 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 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 clockwise to increase the flow until the unit is out of
low flow alarm when the reset switch is pressed and released.
4. Decrease the flow very slowly by turning the sensor flow control valve’s knob
counterclockwise 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.
1/4" Tube
Inside of Case
Outside of Case
O-ring
Fitting Body
Back Ferrule
Tube Nut
Front Ferrule
1/4" Tube
Figure 6: Inlet Fitting with Tubing Stub
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.
NOTE: Calibrating the sample draw detector may cause alarms. Be sure to put the controller into
its calibration program or disable external alarms before continuing.
NOTE: If you can verify a fresh air environment, it is not necessary to use a zero air calibrating
sample to set the zero reading at the controller.
1. Follow the instructions in the controller’s operator’s manual for entering 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. 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 points output for the test sample.
Output (mV) = (calibrating sample/fullscale) X 400 + 100
For example, with a test sample of 25 ppm and a fullscale setting of 100 ppm, the correct
output is 200 mV.
200 (mV) = (25/100) X 400 +100
Setting the Zero Reading
1. Connect the sample tubing from the demand flow regulator to the sample-draw detector’s inlet
fitting. This step is not necessary if you verified a fresh air environment earlier in this
procedure.
06-1248RK-03 Sample tubing, 3/16” ID x 5/16” OD, 3 feet (for calibration kit)
07-0053RK Gasket for hydrogen sulfide flow block
30-1016RK Pump
81-1054RK Regulator, demand flow, for 34 liter aluminum, 58 liter, and 103 liter calibration
cylinders (cylinders with internal threads)
81-1055RK Regulator, demand flow, for 17 liter and 34 liter steel calibration cylinders
(cylinders with external threads)
ES-1537-H2S Hydrogen sulfide sensor