RKI Instruments 35-3001-05-03 Manuale utente

www.rkiinstruments.com

35-3001-05-03

Carbon Dioxide Sample-Draw Detector

Operator’s Manual

Part Number: 71-0413

Revision: 0

Released: 8/4/17

35-3001-05-03 Carbon Dioxide Sample-Draw Detector

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.

35-3001-05-03 Carbon Dioxide 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:

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.

a) Absorbent cartridges d) Batteries

b) Pump diaphragms and valves e) Filter elements

c) Fuses

35-3001-05-03 Carbon Dioxide Sample-Draw Detector

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

External Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Mounting the Carbon Dioxide Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Connecting the Sample Lines to the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Wiring the Carbon Dioxide 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 Carbon Dioxide Sample-Draw Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

35-3001-05-03 Carbon Dioxide Sample-Draw Detector • 1

Overview

This operator’s manual describes the 35-3001-05-03 carbon dioxide 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 carbon dioxide sample-draw detector. See the controller

Operator’s Manual for information specific to the controller.

WARNING: When using the 35-3001-05-03, you must follow the instructions and warnings in

this manual to assure proper and safe operation of the 35-3001-05-03 and to

minimize the risk of personal injury. Be sure to maintain and periodically

calibrate the 35-3001-05-03 as described in this manual.

Table 1: Specifications

Target Gas and Detection Range Carbon Dioxide (CO2): 0 - 5% 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

Inlet Exhaust

100 feet 0 feet

50 feet 50 feet

Maximum Recommended Inlet/

Exhaust Line Length for

1/4” O.D. x 0.170” I.D. Tubing

Inlet Exhaust

100 feet 100 feet

Response Time 90% in 30 seconds

Accuracy ± 5% of reading or ± 2% of full scale (whichever is greater)

2 • 35-3001-05-03 Carbon Dioxide Sample-Draw Detector

Description

This section describes the components of the carbon dioxide sample-draw detector.

Figure 1: Carbon Dioxide Sample-Draw Detector Component Location

Oxygen

Sensor

Terminal

Strip

Pump

Mounting

Foot, 4X

OXY

+ RS

IR CO2

Flow Block

IR CO2

Sensor PCB

Detector/Amp

Terminal Strip

(Factory Wired)

AMP AMP 2

Sensor Flow

Control Valve

Fail LED

Pilot LED

Pump Reset

Switch

Flowmeter

Pressure Switch

Adjustment Screw

(behind PCB)

R BG

Interconnect

Terminal

Strip

OXY

AMP 1

AMP 2

This End To

Inlet Fitting

Flowmeter Circuit

Board Connector

Pump Connector

LEL/ IR

ParticleFilter

LEL/ IR

3/4" Conduit Hub

IR CO2

Sensor

(inside block)

Exhaust

Fitting

Inlet

Fitting EXHAUST

INLET

Hydrophobic

Filter

35-3001-05-03 Carbon Dioxide Sample-Draw Detector • 3

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). 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.

Figure 2: Carbon Dioxide Sample-Draw Detector Flow Diagram

Pump

IR CO2

Sensor

Flowmeter

Particle Filter

Flowmeter PCB

Exhaust Pressure Switch

Hydrophobic Filter

Inlet Restrictor

Sensor

Flow

Control

Valve

4 • 35-3001-05-03 Carbon Dioxide Sample-Draw Detector

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 carbon dioxide sensor

to the main circuit board.

NOTE: The carbon dioxide 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.

35-3001-05-03 Carbon Dioxide Sample-Draw Detector • 5

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.

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 Carbon Dioxide Sensor/IR Carbon Dioxide Sensor PCB

The carbon dioxide sensor is an infrared type plug-in detector. The carbon dioxide sensor is

installed in the IR carbon dioxide flow block and the IR carbon dioxide flow block is mounted to

the middle of the main circuit board. A small circuit board, the IR carbon dioxide sensor PCB, with

a 4-wire cable mates to the IR carbon dioxide sensor and retains it in the flow block. The cable is

wired to the main PCB. The IR carbon dioxide sensor PCB allows you to replace the sensor without

disconnecting the wiring.

6 • 35-3001-05-03 Carbon Dioxide Sample-Draw Detector

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 Carbon Dioxide 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?

Figure 3: Outline and Mounting Dimensions

Ø.30x.50(4X)MOUNTING

.78

1.13

.40

Pilot Fail

.85

.80

4.50

NOTE: Housing is4.3 inchesdeep

8.88

4.00

6.50

35-3001

www.rkiinstruments.com

Sample Drawing

Gas Detector

8.50

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