RKI Instruments 35-3001A-08-03 User manual

www.rkiinstruments.com
35-3001A-08-03
Methane/Carbon Monoxide
Sample-Draw Detector
Operator’s Manual
Part Number: 71-0412
Revision: 0
Released: 8/8/17

35-3001A-08-03 Methane/Carbon Monoxide 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-08-03 Methane/Carbon Monoxide 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-08-03 Methane/Carbon Monoxide Sample-Draw Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
External Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing Components of the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calibration, IR CH4 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Calibration, CO Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector • 1
Overview
This operator’s manual describes the 35-3001A-08-03 methane/carbon monoxide sample-draw
detector. This manual also describes how to install, start up, maintain, and calibrate the sample-
draw detector when using it with a gas monitoring controller. A parts list at the end of this manual
lists replacement parts and accessories for the sample-draw detector.
Specifications
Table 1 lists specifications for the methane/carbon monoxide sample-draw detector. See the
controller Operator’s Manual for information specific to the controller.
WARNING: When using the 35-3001A-08-03, you must follow the instructions and warnings
in this manual to assure proper and safe operation of the 35-3001A-08-03 and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 35-3001A-08-03 as described in this manual.
Table 1: Specifications
Target Gases and Detection Range Methane: 0 - 100% volume
Carbon Monoxide: 0 - 300 ppm
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
50 feet 0 feet
* RKI Instruments, Inc. does not recommend installing this tubing
size on both the inlet and exhaust.
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 Methane:
± 5% of reading or ± 2% of full scale (whichever is greater)
Carbon Monoxide:
± 5% of reading or ± 5 ppm CO (whichever is greater)

2 • 35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector
Description
This section describes the components of the methane/carbon monoxide sample-draw detector.
Figure 1: Methane/Carbon Monoxide Sample-Draw Detector Component Location
Pump
CO Sensor
(inside block)
Pump Connector
B
_
W
LEL
GBR
W
+
O
X
Y
G
E
N
S
PWR/SIG
IR CH4
Sensor PCB
CO Flow
Block
IR CH4 Sensor
(inside block)
Sensor Flow
Control Valve
Fail LED
Pilot LED
GB
Flowmeter
Pump Reset
Switch
AMP 2
S S
AMP 1
+ +
WG
OXY
+R
AMP OXYAMP 2
This End To
Inlet Fitting
Hydrophobic
Filter
IR CH4
Flow Block
Oxygen
Sensor
Terminal
Strip
Particle Filter
Interconnect
Terminal
Strip
Charcoal
Filter
Flowmeter Circuit
BoardConnector
Inlet
Fitting
Exhaust
Fitting
LEL /IR
W
LEL /IR
3/4" Conduit Hub
CO Amplifier
INLET
EXHAUST
Mounting Foot,4X
IR CH4 Amplifier
+ G B
Pressure Switch
Adjustment Screw
(behind PCB) Detector/Amp
Terminal S trip
(Factory Wired)
W
+S R +
S

35-3001A-08-03 Methane/Carbon Monoxide 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 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: Methane/Carbon Monoxide Sample-Draw Detector Flow Diagram
Restrictor
Pump
IR CH4
Sensor
Carbon
Monoxide
Sensor
Flowmeter
Particle Filter
Sensor Flow
Control Valve
Exhaust
Flowmeter PCB
Pressure Switch
Hydrophobic Filter
Inlet Charcoal
Filter

4 • 35-3001A-08-03 Methane/Carbon Monoxide 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 IR CH4 amplifier and
the CO amplifier to the main circuit board.
NOTE: The IR CH4 amplifier and CO amplifier are 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 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.

35-3001A-08-03 Methane/Carbon Monoxide 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 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 0.6 SCFH (±0.1 SCFH). See
“Adjusting the Low Flow Setting” on page 20 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.
Charcoal Filter
A charcoal filter is located at the top of the main circuit board. It scrubs out interfering gases which
may cause the CO sensor to respond, such as H2S or certain hydrocarbons. Replace the charcoal
filter when false high CO readings are noticed, especially in the presence of H2S.
IR CH4Sensor/IR CH4Sensor PCB
The methane sensor is an infrared type plug-in detector. It is installed in the IR CH4 flow block and
the IR CH4 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. A small circuit board, the IR CH4 sensor PCB, with
a 4-wire cable mates to the IR CH4 sensor and retains it in the flow block. The cable is wired to the
IR CH4 amplifier. The IR CH4 sensor PCB allows you to replace the sensor without disconnecting
the wiring.

6 • 35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector
IR CH4Amplifier
The IR CH4 amplifier converts the electrical output from the IR CH4 sensor 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. 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: IR CH4 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.
Factory Set Pots
Sensor
Current
148mA
WLELGBR
Test Points
100-500 mV Range Zero Pot
Detector
Terminal Strip
Span Pot
Controller
Terminal Strip
S
PWR / SIG

35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector • 7
Carbon Monoxide Sensor/CO Amplifier
The carbon monoxide sensor is a plug-in sensor that plugs into the back of the CO amplifier. The
sensor and amplifier are retained in the flow block by two screws. The flow block is mounted to the
middle of the main circuit board. It is the higher of the two flow blocks mounted to the main circuit
board.
Through a series of chemical and electronic reactions, the CO sensor produces a millivolt output
that is proportional to the detection range of the sample-draw detector. A red wire and a blue wire
extend from the CO amplifier and allow connection to the detector/amp terminal strip.
Figure 4: CO Amplifier Component Location
Zero Pot
The zero pot is located in the lower right corner of the amplifier (see Figure 4). Use a small flat
blade screwdriver to turn the zero pot’s adjustment screw and adjust the amplifier’s zero output
during the start up and calibration procedures. Turn the adjustment screw clockwise to increase the
zero output and counterclockwise to decrease the zero output.
Span Pot
The span pot is located to the left of the zero pot (see Figure 4). Use a small flat blade screwdriver
to turn the span pot’s adjustment screw and adjust the amplifier’s gas response during the
calibration procedure. Turn the adjustment screw clockwise to increase the span output and
counterclockwise to decrease the span output.
Test Points
The test points are on the top edge of the amplifier (see Figure 4). The test points produce a 100 mV
to 500 mV output that corresponds to the sample-draw detector’s 4 to 20 mA output. Use the test
points and a voltmeter to measure the amplifier’s output during the start-up and calibration
procedures. The black test point (CAL 2) in the upper left corner is the negative (-) test point and
the red test point (CAL 1) in the upper right corner is the positive (+) test point.
Zero Pot
Span Pot
Test Points
100-500 mV Range

8 • 35-3001A-08-03 Methane/Carbon Monoxide 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 5: 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

35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector • 9
2. Close and latch the housing door.
NOTE: The sample-draw detector is shipped with the mounting feet “tucked under” the housing
to protect the mounting feet during shipment.
3. Slightly loosen the screw that secures the mounting foot to the housing, then rotate the
mounting foot 180 degrees (see Figure 5).
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 7 for the fitting layout.
Installing the Inlet Line with Particle Filter Connected to the Inlet Fitting
1. Loosen the nut on the inlet fitting until 3 threads are visible.
2. Push the particle filter’s tubing stub into the inlet fitting until it stops. Be sure the arrow on the
particle filter is pointing toward the inlet fitting.
3. Hand tighten the nut on the inlet fitting so the ferrules clamp on the tubing. If the tube nut is
removed, see Figure 7 for the arrangement of the fitting components.
4. Connect a length of sample tubing to the other side of the particle filter and route it to the
sampling area. 1/4” O.D. rigid polypropylene, Teflon, or flexible polyurethane tubing may be
used. RKI Instruments, Inc. recommends using either 1/4” O.D. x 1/8” I.D. or 1/4” O.D. x
0.170” I.D. tubing based on your length requirements. See “Specifications” on page 1 for
maximum tubing lengths based on tubing size.
CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate
insert if necessary to provide support to the tubing and ensure a good seal when
connecting to the flexible stub on the filter.
CAUTION: Avoid loops or slumps in the incoming sample line. To reduce response time, keep the
incoming sample line as short as possible.
Installing the Inlet Line without Particle Filter Connected to the Inlet Fitting
1. Loosen the nut on the inlet fitting until 3 threads are visible.
2. Push 1/4” O.D. rigid polypropylene or rigid Teflon sample tubing into the fitting until it stops.
Flexible polyurethane tubing may be used with an appropriate insert. RKI Instruments, Inc.
recommends using either 1/4” O.D. x 1/8” I.D. or 1/4” O.D. x 0.170” I.D. tubing based on your
length requirements. See “Specifications” on page 1 for maximum tubing lengths based on
tubing size.
CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate
insert to seal the connection between the tubing and the inlet fitting.

10 • 35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector
3. Hand tighten the nut on the inlet fitting so the ferrules clamp on the tubing. If the tube nut is
removed, see Figure 7 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 7 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 five-conductor, shielded cable or five 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
6.
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-08-03 Methane/Carbon Monoxide Sample-Draw Detector • 11
8. Connect the wires to the applicable detector/transmitter terminal strip at the controller as
shown in Figure 6. Refer to the controller operator’s manual and the controller detector head
specification sheet for the 35-3001A-08-03 for detector/terminal strip connections specific to
the controller.
Figure 6: 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.
Black
White
Red
Not Usedon
This Version
SP AN
ZERO
Red (+)
Blue (S)
S
PWR/SIG
Green
Black
Red
LEL/IR
LEL/IR
AMP 2AMP 1
AMP 1 AMP 2
PATS201PATS201
White
PATS101PATS101
CO
IR CH4
Sensor OXY
OXY
- (DC Ground)
Controller or Recording Device
4/20 Signal
+24VDC
4/20 Signal
+24VDC
IR CH4
WLELGBR
Sensor
Current
148mA
IR CH4
Sensor PCB

12 • 35-3001A-08-03 Methane/Carbon Monoxide 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.
NOTE: When first powered up, the sample-draw detector will enter about a one minute period
when the 4-20 mA output is stabilizing and may be above the controller alarm points or
well below zero momentarily. RKI controllers have a one minute warmup period when
the controller does not display any gas reading or give any alarm indication. The CO2
transmitter’s 4-20 mA signal should be stable by the time the controller’s warmup period
is over.
6. Verify that the flowmeter indicates a flow rate of approximately 1.0 SCFH. If necessary, use
the sensor flow control valve to adjust the flow rate. Turn the valve’s knob 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 flowmeter ball
drops to the bottom of the flowmeter, the incoming sample line is not leaking.
8. Remove your thumb from the sample line, release the reset switch, and verify the flowmeter
returns to a normal flow rate.
9. Enable alarms or place the controller in normal operation.
CAUTION: Allow the sample-draw detector to warm up for 5 minutes before you continue with
the next section, “Setting the Zero Reading.”

35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector • 13
Setting the Zero Reading
CAUTION: If you suspect the presence of combustible or toxic gas or an abnormal oxygen
concentration in the monitoring environment, use the calibration kit and the zero air
calibration cylinder to introduce “fresh air” to the sensor and verify an accurate
zero setting. See “Calibration, IR CH4Sensor” on page 22 and “Calibration, CO
Sensor” on page 24 for instructions on using a zero air calibration cylinder for
setting the zero reading.
1. Verify that the sample-draw detector is sampling a fresh air environment (environment known
to be free of combustible and toxic gas and of normal oxygen concentration, 20.9%).
2. Verify a reading of 0 %vol for the methane channel and 0 ppm for the CO channel on the
controller display screen for the applicable channel.
If the display reading is 0 %vol for the methane channel and 0 ppm for the CO channel, start up
is complete. The sample-draw detector is in normal operation. If the display reading is not
0 %vol for the methane channel or 0 ppm for the CO channel, continue with step 3.
3. Perform a zero (fresh air) operation at the controller. See “Calibration, IR CH4 Sensor” on
page 22 and “Calibration, CO Sensor” on page 24 for instructions to perform a zero (fresh air)
operation.
Maintenance
This section describes maintenance procedures. It includes preventive maintenance procedures.
This section also includes procedures to troubleshoot the sample-draw detector, replace
components of the sample-draw detector, adjust the low flow setting, and remove the particle
filter’s tubing stub.
Preventive Maintenance
This section describes a preventive maintenance schedule to ensure the optimum performance of
the sample-draw detector. It includes daily, monthly, and quarterly procedures.
Daily Visual Checks
1. Verify that the Pilot LED is on.
2. Verify that the flowmeter indicates a flow rate of approximately 1.0 SCFH. If necessary use the
sensor flow control valve to adjust the flow rate to 1.0 SCFH. Turn the valve’s knob clockwise
to increase the flow and counterclockwise to decrease the flow.
3. Verify a display reading of 0 %vol for the methane channel and 0 ppm for the carbon monoxide
channel at the controller. Investigate significant changes in the display reading.

14 • 35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector
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
NOTE: This procedure describes the RKI calibration kit that includes a demand flow regulator.
1. Verify that the display reading at the controller is 0 %vol for the methane channel and 0 ppm
for the carbon monoxide channel.
If the display reading is not 0 %vol for the methane channel or 0 ppm for the carbon monoxide
channel, set the zero reading as described in “Calibration, IR CH4 Sensor” on page 22 or
“Calibration, CO Sensor” on page 24, then continue this procedure.
2. Set a voltmeter to measure in the millivolt (mV) range.
3. Open the housing door, then plug the voltmeter leads into the test points on the IR CH4
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 %volume and a fullscale setting of 100 %volume, the
correct output is 300 mV.
300 (mV) = (50/100) X 400 +100
Performing the response test
1. Screw the demand flow regulator into the methane cylinder.
2. Connect the calibration tubing from the demand flow regulator to the inlet fitting. Gas will
begin to flow.
3. After approximately one minute, verify that the millivolt output at the IR CH4 amplifier
stabilizes within ± 20% of the reading determined above. If the reading is not within ± 20% of
the determined value, calibrate the sample-draw detector as described in “Calibration, IR CH4
Sensor” on page 22.
4. Unscrew the methane cylinder from the demand flow regulator.
5. Remove the voltmeter leads from the IR CH4 amplifier.

35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector • 15
6. Plug the voltmeter leads into the test points on the CO amplifier.
Plug the positive lead into the red (+) test point; plug the negative lead into the black (-) test
point.
7. 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 ppm CO and a fullscale setting of 300 ppm CO, the
correct output is 167 mV.
167 (mV) = (50/300) X 400 +100
8. Screw the demand flow regulator into the CO calibration cylinder.
9. Connect the calibration tubing from the demand flow regulator to the inlet fitting. Gas will
begin to flow.
10. After approximately one minute, verify that the millivolt output at the CO amplifier stabilizes
within ± 20% of the reading determined above. If the reading is not within ± 20% of the
determined value, calibrate the sample-draw detector as described in “Calibration, CO Sensor”
on page 24.
11. Unscrew the CO cylinder from the demand flow regulator.
12. Remove the calibration tubing from the inlet fitting.
13. Remove the voltmeter leads from the CO amplifier.
14. Close the housing door.
15. Store the calibration kit in a safe place.
16. Reconnect the sample tubing to the inlet fitting.
Quarterly Calibration
Calibrate the sample-draw detector as described in “Calibration, IR CH4 Sensor” on page 22 and
“Calibration, CO Sensor” on page 24.
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.

16 • 35-3001A-08-03 Methane/Carbon Monoxide Sample-Draw Detector
Recommended action
1. At the sample-draw detector, set the correct flow rate with the sensor flow control valve.
2. If you cannot set the correct flow rate, check the sample lines for obstructions or kinks.
3. Verify that the sensor wiring is correct and secure. “Wiring the Sample-Draw Detector to a
Controller” on page 10 describes sensor wiring connections.
4. Calibrate the sample-draw detector as described in “Calibration, IR CH4 Sensor” on page 22
and “Calibration, CO Sensor” on page 24.
5. If the fail condition continues, replace the sensor(s) as described in “Replacing Components of
the Sample-Draw Detector” on page 16.
6. If the fail condition continues, contact RKI Instruments, Inc. for further instruction.
Slow or No Response/Difficult or Unable to Calibrate
Symptoms
• The sensor responds slowly or does not respond during the monthly response test.
• Unable to accurately set the zero or response reading during the calibration procedure.
• The sensor requires frequent calibration.
Probable causes
• The calibration cylinder is low, out-dated, or defective.
• If a demand flow regulator calibration kit is used, the demand flow regulator is not functioning
properly.
• The sample-draw detector’s flow rate is too low because of an obstructed sample line, failed
pump, etc.
• The sample-draw detector is malfunctioning.
Recommended action
1. Verify that the calibration cylinder contains an adequate supply of a fresh test sample.
2. If a demand flow regulator calibration kit is used, use a different demand flow regulator to
determine if the original one is functioning properly.
3. If necessary, set the correct flow rate with the sensor flow control valve.
4. If you cannot set the correct flow rate, check the sample line for obstructions or kinks.
5. If the calibration/response difficulties continue, replace the sensor as described later in this
section.
6. If the calibration/response difficulties continue, contact RKI Instruments, Inc. for further
instruction.
Replacing Components of the Sample-Draw Detector
This section includes procedures to replace the IR CH4 sensor, IR CH4 amplifier, carbon monoxide
sensor, carbon monoxide amplifier, charcoal filter, hydrophobic filter, and particle filter.
Replacing the IR CH4Sensor
1. Turn off the controller.
2. Turn off power to the controller.
3. Open the housing door of the sample-draw detector.
4. Unscrew and remove the four screws that secure the IR CH4 sensor PCB, then lift the IR CH4
sensor PCB and sensor off of the flow block.