35-3001-04-01 Carbon Monoxide

Sample-Draw Detector
Operator’s Manual

Part Number: 71-0395

Revision: 0
Released: 8/4/17

www.rkiinstruments.com
 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.

35-3001-04-01 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:

a) Absorbent cartridges d) Batteries

b) Pump diaphragms and valves e) Filter elements

c) Fuses

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or repair
procedures not in accordance with the operator’s manual. This warranty indicates the full extent of
our liability, and we are not responsible for removal or replacement costs, local repair costs,
transportation costs, or contingent expenses incurred without our prior approval.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER
WARRANTIES AND REPRESENTATIONS, EXPRESSED OR IMPLIED, AND
ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF RKI
INSTRUMENTS, INC. INCLUDING BUT NOT LIMITED TO, THE WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN
NO EVENT SHALL RKI INSTRUMENTS, INC. BE LIABLE FOR INDIRECT,
INCIDENTAL, OR CONSEQUENTIAL LOSS OR DAMAGE OF ANY KIND
CONNECTED WITH THE USE OF ITS PRODUCTS OR FAILURE OF ITS
PRODUCTS TO FUNCTION OR OPERATE PROPERLY.
This warranty covers instruments and parts sold to users by authorized distributors, dealers, and
representatives as appointed by RKI Instruments, Inc.
We do not assume indemnification for any accident or damage caused by the operation of this gas
monitor, and our warranty is limited to the replacement of parts or our complete goods.

35-3001-04-01 Carbon Monoxide 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Low Flow Contact Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing Components of the Sample-Draw Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjusting the Low Flow Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removing the Particle Filter’s Tubing Stub, if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting the Response Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

35-3001-04-01 Carbon Monoxide Sample-Draw Detector

Overview
This operator’s manual describes the 35-3001-04-01 carbon monoxide sample-draw detector. This
version of the sample-draw detector has low flow contacts that allow the user to monitor the
detector’s low flow status. This manual also describes how to install, start up, maintain, and
calibrate the sample-draw detector when using it with a gas monitoring controller. A parts list at the
end of this manual lists replacement parts and accessories for the sample-draw detector.

Specifications
Table 1 lists specifications for the carbon monoxide sample-draw detector. See the controller
Operator’s Manual for information specific to the controller.

Table 1: Specifications

Target Gas and Detection Range 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

Voltage Amps

Low Flow Relay Contact Ratings 125 VAC 0.6 A

(resistive load) 30 VDC 1A

110 VDC 0.6 A

Maximum Recommended Inlet/Exhaust Inlet Exhaust

Line Length for
1/4” O.D. x 1/8” I.D. Tubing 100 feet 0 feet
50 feet 50 feet

Maximum Recommended Inlet/Exhaust Inlet Exhaust

Line Length for
1/4” O.D. x 0.170” I.D. Tubing 100 feet 100 feet

Response Time 90% in 30 seconds

Accuracy ± 5% of reading or ± 5 ppm CO (whichever is greater)

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 1

 WARNING: When using the 35-3001-04-01, you must follow the instructions and warnings in
this manual to assure proper and safe operation of the 35-3001-04-01 and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 35-3001-04-01 as described in this manual.

2 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

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

Flowmeter Circuit Mounting Oxygen

Board Connector Foot, 4X Sensor
Terminal
Sensor Strip
Flow W X
O

Control Pump

+
Y
G
Valve B
_
E
N
Connector

Fail LED
Pilot LED
Pump

Pump Reset CO Sensor

Swi tch (inside bl ock)

CO Ampli fi er
Flowmeter

CO Flow
Pressure Block
Swi tch
Adjustment Charcoal
Screw Filter
(behind PCB) + S + S + LO W
AMP AMP 2 OXY F LOW

Hydrophobic
Filter
+ S + S W G
+ LO W
AMP 1 AMP 2 OXY F LOW
Detector/Amp
Terminal S tri p

Interconnect
Terminal
Strip

This End To
Inlet Fitting

3/4" Conduit Hub

Particle Filter

INLET

Inlet
Fitting EXHAUST

Exhaust
Fitting

Figure 1: Carbon Monoxide Sample-Draw Detector Component Location

35-3001-04-01 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.

Exhaust Pressure Switch Flowmeter

Carbon
Monoxide
Flowmeter PCB Sensor
Sensor
Flow
Control
Inlet Restrictor Valve

Charcoal
Filter
Particle Filter Pump

Hydrophobic Filter

Figure 2: Carbon Monoxide Sample-Draw Detector Flow Diagram

4 • 35-3001-04-01 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 CO amplifier to the
main circuit board.

NOTE: The CO 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 and to access the low flow contacts.
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 sensor 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.
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 sensor. Turn the valve’s knob

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 5

 counterclockwise to increase the flow and clockwise to decrease the flow.
Status LEDs
Two status LEDs are above the flowmeter. They are also visible through the window in the housing
door. The green Pilot LED is on when the sample-draw detector is receiving power from the
controller. The red Fail LED is on when the sample flow rate is below the low flow level.
Pressure Switch
The pressure switch is mounted to the back of the flowmeter circuit board. The pressure switch
monitors the flow rate of the incoming gas sample.
If the flow rate falls below the preset low flow level, the pressure switch causes the Fail LED to
turn on and interrupts the signal from the detector. The interrupted detector signal causes a fail
condition at the controller. The low flow level is factory-set at 0.6 SCFH (±0.1 SCFH). See
“Adjusting the Low Flow Setting” on page 19 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 bottom of the main circuit board, behind the hydrophobic filter. 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.

6 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

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.
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.

Test Points
100-500 mV Range

Zero Pot
Span Pot
Figure 3: CO Amplifier Component Location

Zero Pot
The zero pot is located in the lower right corner of the amplifier (see Figure 3). Use a small flat
blade screwdriver to turn the zero pot’s adjustment screw and adjust the amplifier’s zero output
during the start up and calibration procedures. Turn the adjustment screw clockwise to increase the
zero output and counterclockwise to decrease the zero output.
Span Pot
The span pot is located to the left of the zero pot (see Figure 3). Use a small flat blade screwdriver
to turn the span pot’s adjustment screw and adjust the amplifier’s gas response during the
calibration procedure. Turn the adjustment screw clockwise to increase the span output and
counterclockwise to decrease the span output.
Test Points
The test points are on the top edge of the amplifier (see Figure 3). The test points produce a 100 mV
to 500 mV output that corresponds to the sample-draw detector’s 4 to 20 mA output. Use the test
points and a voltmeter to measure the amplifier’s output during the start-up and calibration
procedures. The black test point (CAL 2) in the upper left corner is the negative (-) test point and
the red test point (CAL 1) in the upper right corner is the positive (+) test point.

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 7

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?
6.50
Ø .30 x .50 (4X) M OUNTING
1.13

.40 4.00

.78

Pilot Fail

Sample Drawing
Gas Detector

8.50 35-3001 8.88

www.rkiinstruments.com

.80

.85
4.50

NOTE: Housing is 4.3 inches deep

Figure 4: Outline and Mounting Dimensions

8 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

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 4).
4. Tighten the screw that secures the mounting foot to the housing.
5. Repeat steps 3 and 4 for the remaining three mounting feet.
6. Position the sample-draw housing on a vertical surface at eye level (4 1/2 to 5 feet from the
floor).
7. Insert 1/4 inch screws through the slots in the mounting feet to secure the housing to the
mounting surface.
Connecting the Sample Lines to the Sample-Draw Detector
See Figure 6 for the fitting layout.
Installing the Inlet Line with Particle Filter Connected to the Inlet Fitting
1. Loosen the nut on the inlet fitting until 3 threads are visible.
2. Push the particle filter’s tubing stub into the inlet fitting until it stops. Be sure the arrow on the
particle filter is pointing toward the inlet fitting.
3. Hand tighten the nut on the inlet fitting so the ferrules clamp on the tubing. If the tube nut is
removed, see Figure 6 for the arrangement of the fitting components.
4. Connect a length of sample tubing to the other side of the particle filter and route it to the
sampling area. 1/4” O.D. rigid polypropylene, Teflon, or flexible polyurethane tubing may be
used. RKI Instruments, Inc. recommends using either 1/4” O.D. x 1/8” I.D. or 1/4” O.D. x
0.170” I.D. tubing based on your length requirements. See “Specifications” on page 1 for
maximum tubing lengths based on tubing size.

CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate
insert if necessary to provide support to the tubing and ensure a good seal when
connecting to the flexible stub on the filter.

CAUTION: Avoid loops or slumps in the incoming sample line. To reduce response time, keep the
incoming sample line as short as possible.

Installing the Inlet Line without Particle Filter Connected to the Inlet Fitting
1. Loosen the nut on the inlet fitting until 3 threads are visible.
2. Push 1/4” O.D. rigid polypropylene or rigid Teflon sample tubing into the fitting until it stops.
Flexible polyurethane tubing may be used with an appropriate insert. RKI Instruments, Inc.
recommends using either 1/4” O.D. x 1/8” I.D. or 1/4” O.D. x 0.170” I.D. tubing based on your
length requirements. See “Specifications” on page 1 for maximum tubing lengths based on
tubing size.

CAUTION: If you use flexible sample tubing (polyurethane is acceptable), use an appropriate
insert to seal the connection between the tubing and the inlet fitting.

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 9

 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. 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 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
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.

10 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

 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 35-3001-04-01 for detector/terminal strip connections specific to the
controller.

Not U sed in
This V ersion

B lue ( S)

Red ( +)

AMP 1 AMP 2 OXY LOW

FLOW

Low F low

1
0
2
S
T
A
P
Relay Contact Ratings:
125 VAC 0.6A
0
1
S
T
A
P
30 V DC 1A LOW
110 VDC 0.6A AMP 1 AMP 2
OXY
FLOW

+ 24 V DC
Controller or 4/20 Signal
OR
Recording - (DC G round)
Dev ice
Power

Contact
Resistive Monitori ng
Load Device Dev ice

Figure 5: Wiring the Sample-Draw Detector to a Controller

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 11

 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.
10. Connect a contact monitoring device or some other device to the low flow contacts. Do not
exceed the relay ratings below. The ratings are for a resistive load.

Table 2: Low Flow Relay Specifications

Voltage Amps

125 VAC 0.6 A

30 VDC 1A

110 VDC 0.6 A

See “Low Flow Contact Operation” on page 13 for a description of how to use the low flow
contacts.

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 1.0 SCFH. If necessary, use
the sensor flow control valve to adjust the flow rate. Turn the valve’s knob counterclockwise to
increase the flow and clockwise 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.

12 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

 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

CAUTION: If you suspect the monitoring environment is not a fresh air area, 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” on page 21 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 toxic gasses).
2. Open the housing door.
3. Set a voltmeter to measure in the millivolt (mV) range.
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.

Low Flow Contact Operation

The low flow contact is closed during normal operation and opens during a low flow condition or if
the sample-draw detector loses power.
Monitoring of the low flow contacts can be done with a contact monitoring device that does not
exceed the relay ratings below. Alternatively, the contacts could be used to power a device that does
not exceed the relay contact ratings below. The ratings are for a resistive load.

Table 3: Low Flow Relay Specifications

Voltage Amps

125 VAC 0.6 A

30 VDC 1A

110 VDC 0.6 A

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 13

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
counterclockwise to increase the flow and clockwise to decrease the flow.
3. Verify a display reading of 0 ppm at the controller. Investigate significant changes in the
display reading.
Monthly Response Test
This procedure describes a test to verify that the sample-draw detector responds properly to the
target gas.

NOTE: To reduce the response time of this test, use a short incoming sample line. If the sample-
draw detector’s sample line is long, connect a shorter line for this test. Make sure you
reconnect the sample line after you complete this procedure.

NOTE: Performing a response test on the sample-draw detector may cause alarms. Be sure to put
the controller into its calibration program or disable external alarms before performing
this test.

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 ppm.

If the display reading is not 0 ppm, set the zero reading as described in “Calibration” on
page 21, 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 CO amplifier.
Plug the positive lead into the red (+) test point; plug the negative lead into the black (-) test
point.

14 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

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 ppm and a fullscale setting of 300 ppm, the correct
output is 167 mV.
167 (mV) = (50/300) X 400 +100
Performing the response test
1. Screw the demand flow regulator into the carbon monoxide calibration 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 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” on page 21.
4. Remove the calibration tubing from the inlet fitting.
5. Remove the voltmeter leads from the CO amplifier.
6. Close the housing door.
7. Reconnect the sample tubing to the inlet fitting.
8. Store the calibration kit in a safe place.
Quarterly Calibration
Calibrate the sample-draw detector as described in “Calibration” 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.
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” on page 21.

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 15

 5. If the fail condition continues, replace the sensor 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.
Unexplained Readings
Symptoms
Controller shows carbon monoxide readings when there is no carbon monoxide present.
Probable causes
The charcoal filter is saturated and is no longer scrubbing out interfering gases.
Recommended action
Replace the charcoal filter.
Replacing Components of the Sample-Draw Detector
This section includes procedures to replace the carbon monoxide sensor, CO amplifier,
hydrophobic filter, and particle filter.
Replacing the CO Sensor
1. Turn off the controller.
2. Turn off power to the controller.
3. Open the housing door of the sample-draw detector.
4. Unscrew the two screws in the upper right and lower left corners of the CO flow block then lift

16 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

 the CO amplifier and sensor off of the flow block.
There is a gasket at the bottom of the flow block. Be sure the gasket stays in place.
5. Unplug the sensor from the CO amplifier.
6. Verify that you are using the correct replacement sensor, then plug the sensor into the CO
amplifier.
7. Place the sensor and amplifier in the CO sensor cavity.
8. Secure the CO amplifier on the flow block with the two screws you removed in step 4.
9. Close and latch the housing door.
10. Turn on power to the controller.
11. Turn on the controller.
12. Allow the sample-draw detector to warmup for 5 minutes.
13. Calibrate the replacement sensor as described in “Calibration” on page 21.
Replacing the CO Amplifier
1. Turn off the controller.
2. Turn off power to the controller.
3. Open the housing door of the sample-draw detector.
4. Disconnect the red and blue wires coming from the CO amplifier from the AMP 1 position on
the detector/amp terminal strip.
5. Unscrew the two screws in the upper right and lower left corners of the CO flow block then lift
the CO amplifier and sensor off of the flow block.
There is a gasket at the bottom of the flow block. Be sure the gasket stays in place.
6. Disconnect the sensor from the CO amplifier.
7. Plug the CO sensor into the new CO amplifier.
8. Place the sensor and amplifier in the CO sensor cavity.
9. Secure the CO amplifier on the flow block with the two screws you removed in step 5.
10. Reconnect the wires coming from the CO amplifier to the AMP 1 position on the detector/amp
terminal strip.
Connect the red wire to the “+” terminal. Connect the blue wire to the “S” terminal.

NOTE: When the sample-draw detector is first powered up with a new amplifier, the initial
output may be either high or below zero depending on the setting of the span pot. Be sure
to make arrangements so that this does not cause unwanted alarms.

11. Turn on power to the controller.

12. Turn on the controller and place it into normal operation.
13. Allow the sample-draw detector to warmup for 5 minutes.
14. Calibrate the sample-draw detector as described in “Calibration” on page 21.
Replacing the Charcoal Filter
1. Turn off the controller.
2. Turn off power to the controller.
3. Open the housing door of the sample-draw detector.

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 17

 4. The hydrophobic filter partially covers the charcoal filter. Move the hydrophobic filter up and
to the left so that it is out of the way.
5. Pull the charcoal filter away from the main circuit board so that it is easier to access.
6. Disconnect the filter from the rubber elbows on each end of the filter, then remove the filter
from the sample-draw detector.
7. Install the new filter. If there is an arrow on the filter, be sure that it’s pointing in the direction
of flow which is toward the tubing that goes to the CO sensor flow block inlet.
8. Arrange the charcoal filter and the hydrophobic filter as shown in Figure 1.
9. Turn on power to the controller.
10. Turn on the controller and place it into normal operation.
11. Verify that the flow rate is approximately 1.0 SCFH, then close the housing door.
Replacing the Hydrophobic Filter
1. Turn off the controller.
2. Turn off power to the controller.
3. Open the housing door of the sample-draw detector.
4. Disconnect the filter from the rubber elbows on each end of the filter, then remove the filter
from the sample-draw detector.
5. Install the new filter. Be sure the side of the filter marked “INLET” is connected to the elbow
that is connected to the inlet fitting.
6. Turn on power to the controller.
7. Turn on the controller and place it into normal operation.
8. Verify that the flow rate is approximately 1.0 SCFH, then close the housing door.
Replacing the Particle Filter
1. Turn off the controller.
2. Turn off power to the controller.
3. If the particle filter is installed at the inlet fitting:
1. Disconnect the tubing routed to the sampling area, if installed, from the particle filter.
2. Disconnect the particle filter from the tubing stub.
3. Install the new particle filter onto the tubing stub. Be sure the arrow on the particle filter is
pointing toward the inlet fitting.
4. Reinstall the tubing routed to the sampling area.
4. If the particle filter is installed at the end of the inlet line:
1. Remove the particle filter from the tubing stub.
2. Install the new particle filter onto the tubing stub. Be sure the arrow on the particle filter is
pointing toward the inlet line.
5. Turn on power to the controller.
6. Turn on the controller.

18 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

Adjusting the Low Flow Setting

NOTE: Adjusting the low flow setting will cause a low flow alarm at the sample-draw detector
and a fail alarm at the controller. Be sure to put the controller into its calibration program
or disable external alarms before performing this test.

The factory-set low flow setting is 0.6 SCFH (±0.1). To adjust the low flow setting:
1. Use the sensor flow control valve to set the flow to 0.6 SCFH. Turn the valve’s knob
counterclockwise to increase the flow and clockwise to decrease the flow.
If the sample-draw detector goes into low flow alarm before you can adjust the flow down to
0.6 SCFH, adjust the pressure switch adjustment screw 1/4 turn clockwise, then attempt to set
the flow again. Repeat this step until you are able to adjust the flow to 0.6 SCFH.

NOTE: The pressure switch adjustment screw is accessible through a circular cutout in the
flowmeter circuit board.

2. Slowly turn the pressure switch adjustment screw counterclockwise just until the sample-draw
detector goes into low flow alarm.
3. Turn the sensor flow control valve’s knob counterclockwise to increase the flow until the unit
is out of low flow alarm when the reset switch is pressed and released.
4. Decrease the flow very slowly by turning the sensor flow control valve’s knob clockwise and
verify that the low flow alarm is 0.6 SCFH (±0.1).
If the low flow alarm is set too high, turn the pressure switch adjustment screw slightly
clockwise. Repeat steps 3 and 4 if necessary.
5. Use the sensor flow control valve to set the flow to 1.0 SCFH.
6. Make sure the sample-draw detector’s Fail LED is off.

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 19

 Removing the Particle Filter’s Tubing Stub, if Necessary
A short tubing stub comes factory installed in the particle filter. It is used for connecting the particle
filter to the inlet fitting. If you have installed the particle filter and no longer want it installed, you
will need to remove the particle filter’s tubing stub from the inlet fitting and replace it with tubing.

1/4" Tube

Inside of Case

Outside of Case

O-ring
Fitting Body

Back Ferrule
Tube Nut
Front Ferrule

1/4" Tube
Figure 6: Inlet Fitting with Tubing Stub

CAUTION: Do not pull the tubing stub downward to remove it.

1. Remove the particle filter from its tubing stub.

2. Unscrew the outside inlet fitting tube nut from the fitting body. The tubing stub should come
out with the tube nut. Be careful not to lose the O-ring that may come out with the tubing stub.
If you do lose the O-ring or if it is damaged, see “Parts List” on page 23 for the spare part
number.
3. Push the tubing stub up and out of the front ferrule being careful not to lose the ferrule set. If
you do lose the ferrule set or if it is damaged, see “Parts List” on page 23 for the spare part
numbers.
4. Push the new tubing up through the inlet fitting tube nut and replace the ferrule set and the O-
ring, if it came out, in the orientation shown in Figure 6.
5. Screw the inlet fitting tube nut back onto the fitting body. See “Connecting the Sample Lines to
the Sample-Draw Detector” on page 9 for instructions to install a new piece of tubing into the
fitting.

20 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

Calibration Frequency
Although there is no particular calibration frequency that is correct for all applications, a calibration
frequency of every 3 months is adequate for most carbon monoxide sample draw detector
applications. Unless experience in a particular application dictates otherwise, RKI Instruments, Inc.
recommends a calibration frequency of every 3 months for the carbon monoxide sample draw
detector.
If an application is not very demanding, for example detection in a clean, temperature controlled
environment, and calibration adjustments are minimal at calibration, then a calibration frequency of
every 6 months is adequate.
If an application is very demanding, for example if the environment is not well controlled, then
more frequent calibration than every 3 months may be necessary.

Calibration
This section describes how to calibrate the carbon monoxide sensor in the sample-draw detector. It
includes procedures to prepare for calibration, set the zero reading, set the response reading, and
return to normal operation.

NOTE: Calibrating the sample draw detector may cause alarms. Be sure to put the controller into
its calibration program or disable external alarms before continuing.

NOTE: This procedure describes calibration using a demand flow regulator.

Preparing for Calibration

NOTE: If you can verify a fresh air environment, it is not necessary to use a zero air calibrating
sample to set the zero reading at the controller.

1. Follow the instructions in the controller’s operator’s manual for entering calibration mode.
2. Screw the regulator into the zero air calibration cylinder.
3. Open the housing door.
4. Set a voltmeter to measure in the millivolt (mV) range.
5. Plug the positive lead into the red (+) amplifier test point; plug the negative lead into the black
(-) amplifier test point.
6. Use the following formula to determine the correct test points output for the test sample.
Output (mV) = (calibrating sample/fullscale) X 400 + 100
For example, with a test sample of 50 ppm and a fullscale setting of 300 ppm, the correct
output is 167 mV.
167 (mV) = (50/300) X 400 +100
Setting the Zero Reading
1. Connect the sample tubing from the demand flow regulator to the sample-draw detector’s inlet
fitting. This step is not necessary if you verified a fresh air environment earlier in this
procedure.

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 21

 2. Allow the sample draw detector to draw sample for one minute.
3. Verify a voltmeter reading of 100 mV (± 2 mV).
4. If necessary, use a small flat-blade screwdriver to adjust the zero potentiometer until the
voltmeter reading is 100 mV (± 2 mV). If you used a zero air calibration cylinder to set the
zero reading, proceed to step 5. If you verified a fresh air environment, proceed to the next
section, Setting the Zero Reading.
5. Disconnect the sample tubing from the inlet fitting.
6. Unscrew the regulator from the zero air calibration cylinder.
Setting the Response Reading
1. Screw the demand flow regulator onto the carbon monoxide calibration cylinder.
2. Connect the sample tubing from the regulator to the inlet line.
3. Allow the sample-draw detector to draw the calibrating sample for 1 minute.
4. When the reading on the voltmeter stabilizes, verify that the reading matches the response
reading (±2 mV) you determined earlier.
5. If necessary, use the span potentiometer on the amplifier to adjust the reading to match the
correct response reading.
6. Disconnect the sample tubing from the sample-draw detector’s inlet fitting.
7. Reconnect the incoming sample line to the inlet fitting.
8. Unscrew the regulator from the calibration cylinder.
Returning to Normal Operation
1. Wait approximately one minute to allow the carbon monoxide reading to stabilize.
2. Remove the voltmeter leads from the amplifier test points.
3. Close the housing door.
4. Follow the instructions in the controller’s operator’s manual to exit the calibration mode.
5. Store the components of the calibration kit in a safe and convenient place.

22 • 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

Parts List
Table 4 lists replacement parts and accessories for the sample-draw detector.

Table 4: Parts List

Part Number Description

06-1248RK Sample tubing, 3/16 in. ID x 5/16 in. OD, specify length

06-1248RK-03 Sample tubing, 3/16 in. ID x 5/16 in. OD, 3 feet (for calibration kit)
07-0053RK Gasket for carbon monoxide flow block

17-2670 Inlet fitting O-ring

17-2671 Inlet fitting front ferrule

17-2672 Inlet fitting back ferrule and tube nut

30-1016RK Pump

33-0165RK Hydrophobic filter

33-0167RK Particle filter

33-6098 Charcoal filter

71-0395 Operator’s Manual, 35-3001-04-01 Carbon Monoxide Sample-Draw Detector

81-0064RK-01 Calibration cylinder, 50 ppm CO in air, 34 liter steel

81-0064RK-03 Calibration cylinder, 50 ppm CO in air, 103 liter

81-0076RK-01 Zero air calibration cylinder, 34 liter steel

81-0076RK-03 Zero air calibration cylinder, 103 liter

81-1054RK Regulator, demand flow, for 34 liter aluminum, 58 liter, and 103 liter calibration
cylinders (cylinders with internal threads)

81-1055RK Regulator, demand flow, for 17 liter and 34 liter steel calibration cylinders
(cylinders with external threads)

ES-1531-CO Carbon monoxide sensor

35-3001-04-01 Carbon Monoxide Sample-Draw Detector • 23