RKI Instruments 35-3001-06H-DIL User manual

www.rkiinstruments.com
35-3001-06H-DIL
Hydrogen/Oxygen
Sample-Draw Detector
Operator’s Manual
Part Number: 71-0346
Revision: A
Released: 8/7/17

35-3001-06H-DIL Hydrogen/Oxygen 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
3 and 6 months, but can be required more often or less often
based on your usage.

35-3001-06H-DIL Hydrogen/Oxygen 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

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
External Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting the Sample Lines to the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wiring the Sample-Draw Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacing Components of the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calibration, LEL Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Calibration, Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting the Fresh Air Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector • 1
Overview
This operator’s manual describes the 35-3001-06H-DIL hydrogen/oxygen 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.
About the 35-3001-06H-DIL
The 35-3001-06H-DIL is designed to monitor hydrogen and oxygen in an inerted area (an area that
has no, or almost no, oxygen present). The catalytic LEL sensor used to detect hydrogen must have
at least 5% oxygen present to detect gas properly. A dilution fitting installed in the flow system
after the oxygen sensor and before the LEL sensor allows enough air to enter the gas sample so that
the LEL sensor has enough oxygen to function properly. The dilution ratio is approximately 1:1 but
will vary slightly with increased sample line lengths. The longer the sample line, the more dilution
air will enter the gas sample through the dilution fitting. Because of this, it is important when
calibrating the detector head to apply the calibration gas to the sample line inlet if a sample line is
installed. In addition, because the detector head includes internal dilution, it must be calibrated
using a sample bag instead of a demand flow regulator. See “Calibration, LEL Sensor” on page 19
and “Calibration, Oxygen Sensor” on page 21 for detailed calibration instructions.
Specifications
Table 1 lists specifications for the hydrogen/oxygen sample-draw detector. See the controller
Operator’s Manual for information specific to the controller.
Table 1: Specifications
Target Gases and Detection Range Hydrogen: 0 - 100% LEL
Oxygen: 0 - 25% 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 2.7 SCFH typical, with no inlet or exhaust line
Low Flow Setpoint 1.0 ± 0.1 SCFH, measured in the sample inlet line
Sensor Flow 0.8 SCFH (nominal)
Maximum Recommended Inlet/
Exhaust Line Length for
1/4” O.D. x 1/8” I.D. Tubing
Inlet Exhaust
50 feet 0 feet
* RKI Instruments, Inc. does not recommend installing this tubing
size on both the inlet and exhaust.

2 • 35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector
WARNING: When using the 35-3001-06H-DIL, you must follow the instructions and
warnings in this manual to assure proper and safe operation of the 35-3001-06H-
DIL and to minimize the risk of personal injury. Be sure to maintain and
periodically calibrate the 35-3001-06H-DIL as described in this manual.
Maximum Recommended Inlet/
Exhaust Line Length for
1/4” O.D. x 0.170” I.D. Tubing
Inlet Exhaust
50 feet 50 feet
75 feet 0 feet
Response Time 90% in 30 seconds
Accuracy Hydrogen:
± 5% of reading or ± 2% LEL (whichever is greater)
Oxygen:
± 0.5% O2
Table 1: Specifications

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector • 3
Description
This section describes the components of the hydrogen/oxygen sample-draw detector.
Figure 1: Hydrogen/Oxygen Sample-Draw Detector Component Location
B
+
W
Oxygen
Sensor
Oxygen
Sensor
Terminal
Strip
Pump
BG
_
O
X
Y
G
E
N
OXY
+
S
Dilution
Fitting
LEL Flow
Block
LEL Sensor
W
++
AMP AMP 2
S
Sensor Flow
Control Valve
FailLED
Pilot LED
Pump Reset
Switch
Pressure
Switch
Adjustment
Screw
(behind PCB)
Flowmeter
W BG
Interconnect
Terminal
Strip
S
OXY
GW
+
AMP 2
+
AMP 1
+S
Hydrophobic
Filter
Pump Connector
LEL/ IR
R
R
Flowmeter Circuit
Board Connector
Particle Filter
Exhaust
Fitting
Inlet
Fitting
ThisEnd To
Inlet Fitting
LEL/ IR
Oxygen
Flow
Block
Mounting
Foot, 4X
3/4" Conduit Hub
EXHAUST
INLET
Detector/Amp
Terminal Strip
(Factory
Wired)

4 • 35-3001-06H-DIL Hydrogen/Oxygen 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). 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 8 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: Hydrogen/Oxygen Sample-Draw Detector Flow Diagram
Oxygen
Sensor
LEL
Sensor
Flowmeter
Particle Filter
Exhaust
Pump Restrictor
Sensor Flow
Control Valve
Flowmeter PCB
Pressure Switch
Inlet Dilution Fitting,
approx. 1:1 ratio
Hydrophobic Filter

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector • 5
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 hydrogen sensor to the
main circuit board.
NOTE: The hydrogen sensor is factory-wired to the main circuit board. See the “Installation”
section on page 8 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. Use the oxygen sensor terminal strip to connect the oxygen sensor to the main circuit
board.
NOTE: The oxygen sensor is factory-wired to the main circuit board. See the “Installation”
section on page 8 for all wiring procedures related to 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 8 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 8 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 LEL sensor
which is the sample flow plus the dilution flow. The oxygen sensor’s flow rate is approximately

6 • 35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector
half of what the flowmeter indicates. The flowmeter measures the flow in the range 0.2 to 2.0
SCFH (Standard Cubic Feet per Hour). The optimum flow rate is 0.8 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 detectors. Turn the valve’s knob clockwise to
increase the flow and counterclockwise 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 1.0 SCFH (±0.1 SCFH). See
“Adjusting the Low Flow Setting” on page 17 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.
Oxygen Sensor
The oxygen sensor is installed in a flow block and the flow block is mounted to the middle of the
main circuit board. It is the upper of the two flow blocks mounted to the main circuit board. The
oxygen sensor is retained in the flow block by a bracket with two screws.
The oxygen cell is protected within the sensor assembly. Through a series of chemical and
electronic reactions, the oxygen cell produces a millivolt output that is proportional to the detection
range of the sample-draw detector. The leads extending from the sensor terminate in lugs that
connect to the oxygen terminal strip.
Dilution Fitting
The catalytic hydrogen sensor requires oxygen to operate. In environments where there is not
enough oxygen to operate the hydrogen sensor, the dilution fitting adds sufficient oxygen by
blending ambient air with the incoming sample. The standard dilution fitting dilutes at a ratio of
approximately 1:1 (one part air to one part sample).
Hydrogen Sensor
The catalytic hydrogen sensor detects hydrogen in the %LEL range. It uses a catalytic element for
detection. The reaction of gas with oxygen on the catalyst causes a change in the resistance of the
element which changes the current flowing through it. The current is proportional to the detection
range of the sample-draw detector.
The hydrogen sensor is installed in the flow block and the flow block is mounted to the middle of
the main circuit board. It is the lower of the two flow blocks mounted to the main circuit board. An

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector • 7
O-ring at the bottom of the flow block seals the sensor. The sensor housing includes a sintered
metal flame arrestor on one end that allows gas to diffuse into the sensor. The sensor has a built in
molecular sieve that only allows hydrogen to diffuse into the detector. On the other end, five pins
extend from the sensor and plug into the socket connector. The connector allows you to replace the
sensor without disconnecting the wiring. Four leads extending from the connector allow you to
connect the hydrogen sensor to the main circuit board.
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.

8 • 35-3001-06H-DIL Hydrogen/Oxygen 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 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
2. Close and latch the housing door.
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
GasDetector
8.50

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector • 9
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 the 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 the 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.
3. Hand tighten the nut on the inlet fitting so the ferrules clamp on the tubing. If the tube nut is

10 • 35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector
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 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 eight-conductor, shielded cable or eight 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.

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector • 11
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 35-3001-06H-DIL for detector/terminal strip connections specific to
the controller.
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.
White
Green
Black
Red
LEL/IR
PATS101PATS101PATS201PATS201
LEL/IROXY
Controller Detector/
Transmitter Terminal
Strip, LEL Detector
Terminals
OXY
Black
Green
White
Red
AMP 1
Black (-)
White (+)
AMP 1 AMP 2
White
Green
Controller Detector/Transmitter
Terminal Strip, Oxygen
Detector Terminals
- (DC Ground)
+ 24 VDC
Oxygen
Sensor
Controller Detector/
Transmitter Terminal
Strip Terminals
AMP 2
To LEL
Sensor

12 • 35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector
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 0.8 SCFH. If necessary, use
the sensor flow control valve to adjust the flow rate. Turn the valve’s knob clockwise to
increase the flow and counterclockwise 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 sensor flowmeter
indication drops noticeably, the instrument goes into a low flow alarm, and the Fail LED turns
on, the incoming sample line is not leaking.
NOTE: When the inlet line is plugged for this test, the sensor flowmeter will not go to zero
because the dilution fitting is allowing air to enter the sensor flow. The pressure switch
monitors the sample flow to the inlet, not the sensor flow.
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
Since the 35-3001-06H-DIL monitors an inerted area, in order to set the zero reading, the inlet line
must be moved to a fresh air area, the inlet line must be removed so that sample is being drawn
through the inlet fitting (if the instrument is mounted in a fresh air area), or a zero air cylinder must
be used. If a zero air cylinder is used, see “Calibration, LEL Sensor” on page 19 and “Calibration,
Oxygen Sensor” on page 21 for instructions.
1. Verify that the sample-draw detector is sampling a fresh air environment (environment known
to be free of hydrogen and of normal oxygen concentration, 20.9%).
2. Verify a reading of 0 %LEL for the hydrogen channel and 20.9% for the oxygen channel on the

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector • 13
controller display screen for the applicable channel.
If the display reading is 0 %LEL for the hydrogen channel and 20.9% for the oxygen channel,
start up is complete. The sample-draw detector is in normal operation. If the display reading is
not 0 %LEL for the hydrogen channel or 20.9% for the oxygen channel, continue with step 3.
3. Perform a zero (fresh air) operation at the controller. See “Setting the Zero Reading” on
page 20 (for LEL sensor), “Setting the Fresh Air Reading” on page 21 (for oxygen sensor), and
the controller operator’s manual for instructions to perform a zero (fresh air) operation.
4. If necessary, reinstall the sample line to the inlet fitting or put the end of the sample line back
in the sample location.
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 0.8 SCFH. If necessary use the
sensor flow control valve to adjust the flow rate to 0.8 SCFH. Turn the valve’s knob clockwise
to increase the flow and counterclockwise to decrease the flow.
3. At the controller, verify a display reading of 0 %LEL for the hydrogen channel and an oxygen
level consistent with the inerted sample area. 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.
Preparing for the response test
1. Draw sample from a fresh air environment and verify that the display reading at the controller
is 0 %LEL for the hydrogen channel and 20.9% for the oxygen channel.
If the display reading is not 0 %LEL for the hydrogen channel or 20.9% for the oxygen
channel, set the zero reading as described in “Calibration, LEL Sensor” on page 19 or
“Calibration, Oxygen Sensor” on page 21, then continue this procedure.

14 • 35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector
Performing the response test
1. Screw the fixed flow regulator into the hydrogen calibration cylinder.
2. Attach the gas bag tubing to the regulator on the hydrogen calibration cylinder.
NOTE: A demand flow regulator cannot be used for the response test.
3. Turn the regulator’s on/off knob clockwise to open it. Fill the gas bag.
4. Turn the regulator’s on/off knob counterclockwise to close it.
5. Clamp the gas bag shut and disconnect it from the fixed flow regulator.
6. Connect the sample bag tubing to the end of the inlet line and release the clamp. Gas will begin
to flow.
7. After approximately one minute, verify that the hydrogen 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, LEL Sensor” on
page 19.
8. Remove the gas bag tubing from the inlet line.
9. Store the calibration kit in a safe place.
10. Exhale into the sample-draw detector’s inlet line.
11. Stop exhaling into the sample line, then verify that the oxygen reading at the controller
decreased.
12. If the reading does not decrease, calibrate the sample draw detector as described in
“Calibration, Oxygen Sensor” on page 21.
13. Reconnect the sample tubing to the inlet fitting.
Quarterly Calibration
Calibrate the sample-draw detector as described in “Calibration, LEL Sensor” on page 19 and
“Calibration, Oxygen Sensor” on page 21.
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.

35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector • 15
Recommended action
1. At the sample-draw detector, set the correct sensor flow rate with the sensor flow control
valve.
2. Connect a 0-2 SCFH flowmeter to the inlet fitting or the inlet line and confirm the flow is
above the low flow setpoint of 1 SCFH while holding down the reset switch.
NOTE: RKI Instruments, Inc. offers a 0 -2 SCFH flowmeter but tubing connection fittings must
be user installed to the flowmeter’s 1/8” NPT female fittings.
3. If you cannot set the correct sensor flow rate or confirm a good sample flow, check the sample
lines for obstructions or kinks.
4. Verify that the sensor wiring is correct and secure. “Wiring the Sample-Draw Detector to a
Controller” on page 10 describes sensor wiring connections.
5. Calibrate the sample-draw detector as described in “Calibration, LEL Sensor” on page 19 and
“Calibration, Oxygen Sensor” on page 21.
6. If the fail condition continues, replace the sensor(s) as described in “Replacing Components of
the Sample-Draw Detector” on page 16.
7. 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.
• The fixed 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 dilution fitting is blocked.
• The sample-draw detector is malfunctioning.
Recommended action
1. Verify that the calibration cylinder contains an adequate supply of a fresh test sample.
2. Use a different fixed 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. Check the dilution fitting for obstructions.
6. If the calibration/response difficulties continue, replace the sensor as described later in this
section.
7. If the calibration/response difficulties continue, contact RKI Instruments, Inc. for further
instruction.

16 • 35-3001-06H-DIL Hydrogen/Oxygen Sample-Draw Detector
Replacing Components of the Sample-Draw Detector
This section includes procedures to replace the hydrogen sensor, oxygen sensor, hydrophobic filter,
and particle filter.
Replacing the Hydrogen 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 two screws that secure the sensor retaining plate, then lift the plate,
connector, and sensor out of the housing.
5. Unplug the connector from the sensor.
6. Verify that you are using the correct replacement sensor (NC-6244A is printed on the sensor),
then plug the sensor into the connector.
7. Place the sensor in the hydrogen sensor cavity, then position the retaining plate on the two
standoffs.
8. Secure the retaining plate to the standoffs 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.
CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue.
12. Calibrate the replacement sensor as described in “Calibration, LEL Sensor” on page 19.
Replacing the Oxygen Sensor
1. Turn off the controller.
2. Turn off power to the controller.
3. Open the housing door of the sample-draw detector.
4. Loosen the two screws on the oxygen terminal strip and remove the lugs and wires from the
terminal strip.
5. Unscrew and remove the two screws that secure the sensor retaining plate, then lift the plate
and sensor out of the flow block.
There are two gaskets at the bottom of the flow block. Be sure the gaskets stay in place.
6. Place the replacement sensor in the oxygen flow block, then position the retaining plate on the
two standoffs.
7. Secure the retaining plate to the standoffs with the two screws you removed in step 4.
8. Guide the wires and lugs of the replacement sensor to the oxygen terminal strip and insert each
lug into the appropriate terminal. See Figure 4 on page 11 for wiring connections. Tighten the
screws on the terminal strip.
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.