RKI Instruments 35-3001A-01HDIL User manual

www.rkiinstruments.com
35-3001A-01HDIL
Hydrogen Sample-Draw Detector
Operator’s Manual
Part Number: 71-0410
Revision: 0
Released: 8/7/17

35-3001A-01HDIL Hydrogen 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.

35-3001A-01HDIL Hydrogen 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

35-3001A-01HDIL Hydrogen 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

35-3001A-01HDIL Hydrogen Sample-Draw Detector • 1
Overview
This operator’s manual describes the 35-3001A-01HDIL hydrogen 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 35-3001A-01HDIL
The 35-3001A-01HDIL is designed to monitor hydrogen 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 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” on page 20 for detailed calibration instructions.
Specifications
Table 1 lists specifications for the hydrogen 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
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
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
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

2 • 35-3001A-01HDIL Hydrogen Sample-Draw Detector
WARNING: When using the 35-3001A-01HDIL, you must follow the instructions and
warnings in this manual to assure proper and safe operation of the
35-3001A-01HDIL and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 35-3001A-01HDIL as described in this
manual.
Accuracy ± 5% of reading or ± 2% LEL (whichever is greater)
Table 1: Specifications

35-3001A-01HDIL Hydrogen Sample-Draw Detector • 3
Description
This section describes the components of the hydrogen sample-draw detector.
Figure 1: Hydrogen Sample-Draw Detector Component Location
Pump
Oxygen
Sensor
Terminal
Strip
Mounting
Foot, 4X
W
+
B
O
X
Y
G
E
N
_
S
PWR/SIG
Hydrogen
Flow
Block
Dilution
Fitting
Pilot LED
Fail LED
Sensor Flow
Control Valve
Pump Reset
Switch
Flowmeter
W
Interconnect
Terminal
Strip
+
AMP 1
+
AMP2
S S R
+
WG
OXY
G
Hydrophobic
Filter
Particle
Filter
FlowmeterCircuit
Board Connector
B
LEL/ IR
Hydrogen
Sensor
Inlet
Fitting
Exhaust
Fitting
ThisEnd
To Inlet
Fitting 3/4" Conduit Hub
Sensor
Current
115m A
W
LEL
GBR
EXHAUST
INLET
Pump Connector
Hydrogen Amplifier
AMP 2AMP
+
+W B
Pressure
Switch
Adjustment
Screw
(behind PCB)
Detector/Amp
Terminal Strip
(Factory
Wired)
LEL/ IR
GS R
+
OXY
S

4 • 35-3001A-01HDIL Hydrogen 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 Sample-Draw Detector Flow Diagram
Hydrogen
Sensor
Flowmeter
Particle Filter
Exhaust
Pump Restrictor
Sensor Flow
Control Valve
Flowmeter PCB
Pressure Switch
Inlet Dilution Fitting,
approx. 1:1 ratio
Hydrophobic Filter

35-3001A-01HDIL Hydrogen 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 amplifier to the main
circuit board.
NOTE: The amplifier 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. 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 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 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.

6 • 35-3001A-01HDIL Hydrogen Sample-Draw Detector
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 18 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.
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. An 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 are factory wired to the amplifier.

35-3001A-01HDIL Hydrogen Sample-Draw Detector • 7
Amplifier
The amplifier converts the electrical output from the detector to a 4 to 20 mA signal that
corresponds to the detection range and transmits the signal to a gas monitoring controller. A label
on the amplifier indicates the detector drive current. This drive current is factory set and is dictated
by the combustible gas to which the detector is calibrated. Consult RKI Instruments, Inc. if you
plan to change the calibration gas for the sample-draw detector, for example from a hydrogen
calibration to a methane calibration. The amplifier is mounted on the top middle edge of the main
circuit board. It consists of the zero pot, span pot, controller terminal strip, detector terminal strip,
and test points.
Figure 3: Amplifier Component Location
Zero Pot
The zero pot is located in the upper 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 (fresh air)
output during the start-up and calibration procedures. Turn the adjustment screw clockwise to
increase the fresh air output and counterclockwise to decrease the fresh air output.
Span Pot
The span pot is located below 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 output during the
calibration procedure. Turn the adjustment screw clockwise to increase the span output and
counterclockwise to decrease the span output.
CAUTION: The amplifier includes additional pots. They are factory-set. Do not adjust them.
Controller and Detector Terminal Strips
The controller terminal strip and detector terminal strip are three- and four-position plug-in style
terminal strips, respectively. The controller terminal strip is located on the right side of the
amplifier and the detector terminal strip is to the left of it. Both terminal strips are factory wired to
the sensor and main circuit board.
Test Points
The test points are on the left side 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 in the upper left corner is the negative (-) test point and the red test
point to the left of the zero and span pots is the positive (+) test point.
WLELGBR
Test Points
100-500 mV Range
Controller
Terminal Strip
Span Pot
Zero Pot
Factory Set Pots
S
PWR / SIG
Detector
Terminal Strip

8 • 35-3001A-01HDIL Hydrogen 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 4: 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
Gas Detector
8.50

35-3001A-01HDIL Hydrogen 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 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 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 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 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 • 35-3001A-01HDIL Hydrogen Sample-Draw Detector
removed, see Figure 6 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 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.
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 three-conductor, shielded cable or three 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
5.
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.

35-3001A-01HDIL Hydrogen Sample-Draw Detector • 11
8. Connect the wires to the applicable detector/transmitter terminal strip at the controller as
shown in Figure 5. Refer to the controller operator’s manual and the controller detector head
specification sheet for the 35-3001A-01HDIL for detector/terminal strip connections specific
to the controller.
Figure 5: 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.
Not Used on
This Version
S
PWR / SIG
ZE R O
SPAN
OXY LEL/IR
Green
Black
Red
White
PATS201PATS201
AMP 1
OXY LEL/IR
+ 24 VDC
AMP 1
AMP 2
Controller or
Recording
Device
AMP 2
4/20 Signal
- (DC Ground)
To
Hydrogen
Sensor
PATS101PATS101
WLEL
GBR
Sensor
Current
115m A

12 • 35-3001A-01HDIL Hydrogen 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 35-3001A-01HDIL 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” on page 20 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. Open the housing door.
3. Set a voltmeter to measure in the millivolt (mV) range.

35-3001A-01HDIL Hydrogen Sample-Draw Detector • 13
4. Plug the voltmeter leads into the test points on the amplifier. Plug the positive lead into the red
(+) test point; plug the negative lead into the black (-) test point.
5. Verify a voltmeter reading of 100 mV (± 2 mV).
6. If necessary, use a small flat-blade screwdriver to adjust the zero potentiometer until the
voltmeter reading is 100 mV (± 2 mV).
7. Remove the voltmeter leads from the test points.
8. Close the housing door.
9. 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 at the controller or a reading of 100 mV
at the amplifier test points. 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. Verify that the display reading at the controller is 0 %LEL.
If the display reading is not 0 %LEL, set the zero reading as described in “Calibration” on
page 20, then continue this procedure.
2. Set a voltmeter to measure in the millivolt (mV) range.

14 • 35-3001A-01HDIL Hydrogen Sample-Draw Detector
3. Open the housing door, then plug the voltmeter leads into the test points on the amplifier.
Plug the positive lead into the red (+) test point; plug the negative lead into the black (-) test
point.
4. Use the following formula to determine the correct test points output for the test sample.
Output (mV) = (calibrating sample/fullscale) X 400 + 100
For example, with a test sample of 50 %LEL and a fullscale setting of 100 %LEL, the correct
output is 300 mV.
300 (mV) = (50/100) X 400 +100
Performing the response test
1. Screw the 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 reading on the voltmeter stabilizes within
± 20% of the mV output value calculated above. If the reading is not within ± 20% of the
calculated output, calibrate the sample-draw detector as described in “Calibration” on page 20.
8. Remove the gas bag tubing from the inlet line.
9. Remove the voltmeter leads from the amplifier test points.
10. Store the calibration kit in a safe place.
11. Reconnect the sample tubing to the inlet fitting.
Quarterly Calibration
Calibrate the sample-draw detector as described in “Calibration” on page 20.
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

35-3001A-01HDIL Hydrogen Sample-Draw Detector • 15
pump, etc.
• The sample-draw detector is malfunctioning.
• The sensor and/or amplifier wiring is disconnected or misconnected.
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 1.0 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 and amplifier 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” on page 20.
6. If the fail condition continues, replace the sensor 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 • 35-3001A-01HDIL Hydrogen Sample-Draw Detector
Replacing Components of the Sample-Draw Detector
This section includes procedures to replace the hydrogen sensor, amplifier, 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” on page 20.
Replacing the Amplifier
1. Turn off the controller.
2. Turn off power to the controller.
3. Open the housing door of the sample-draw detector.
4. Remove the detector and controller plug-in terminal strips by grasping the sides of the strips
with your fingers. Let the terminal strips hang by their connected wires while you replace the
amplifier.
5. Unscrew the screw in the lower left corner of the amplifier and remove the screw, lock washer,
and flat washer. Be careful not to lose any of these parts.
6. Remove the old amplifier from the main circuit board.
7. Install the new amplifier in the same orientation as the old amplifier. See Figure 1.
8. Reinstall the screw, lock washer, and flat washer you removed in step 5.