Part Number: 71-0439
Revision: P1
Released: 9/14/17
65-2437RKSS-05
Operator’s Manual
RKI Instruments, Inc.
www.rkiinstruments.com
WARNING
Read and understand this instruction manual before operating
instrument. 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.
65-2437RKSS-05 CO 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 witho u t our prior
approval.
a) Absorbent cartridgesd) Batteries
b) Pump diaphragms and valvese) Filter elements
c) Fuses
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. IN CLUDING BUT NOT LIMITED TO, THE
WARRANTY OF MERCHANTABILITY OR F ITNESS 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 d istributors,
dealers, and representatives as appointed by RKI Instruments, Inc.
We do not assume indemnification for any a ccident or damage caused by the opera tion of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.
This manual describes the 65-2437RKSS-05 carbon monoxide (CO) detector. This manual
also describes how to install, start up, maintain, and calibrate the detector when it is used
with a gas monitoring controller. A parts list at the end of this manual lists replacement
parts and accessories for the CO detector.
Specifications
WARNING: Do not use this product in a manner not specified in this instruction
manual.
Table 1 lists specifications for the CO detector.
Table 1: Specifications
Target GasCarbon Monoxide (CO)
Area ClassificationExplosionproof for Class I, Groups B, C, and D
Temperature CodeT6
Installation CategoryInstallation Category 1. Signal level, special equipm ent or parts of
Sampling MethodDiffusion
Detection Range0 to 300 PPM (parts per million)
CO Detector Signal Output0.3 mA at 0 ppm CO nominal
Response Time90% in 30 seconds
Accuracy± 5% of reading or ± 5 ppm CO (whichever is greater)
Operating Temperature23°F to 104°F (5°C to 40°C)
NOTE: The following symbol on the detector label is a caution to the user to refer to this
documentation for installation and operation instructions:
WARNING: When using the 65-2437RKSS-05, you must follow the instru ctions and
warnings in this manual to assur e proper and safe operation of the
65-2437RKSS-05 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 65-2437RKSS-05 as described in
this manual.
equipment, telecommunication, electron ic, etc., with smaller
transient overvoltages than Installati on Category (Overvoltage
Category) II (ref. I EC 664).
2.5 mA at 300 ppm CO nominal
65-2437RKSS-05 CO D etecto r • 1
Description
Stainless Steel
J-Box
Locking S et Screw
Terminal Block
Red
Black
CO Detector
This section describes the components of the 65-2437RKSS-05 CO detector. The
65-2437RKSS-05 consists of the 65-2438 CO detector and junction box.
Figure 1: CO Detector Component L ocat ion
2 • 65-2437RKSS-05 CO Detector
65-2438 CO Detector
Detector Housing Cap
Rub ber Bo ot Wi th
Charcoal Filter
Plug-In CO Sensor
Cap Gasket
Detector Housing Body
Flame Arrestor
Guard
The 65-2438 CO detector consists of the detector housing body, detector housing cap, cap
gasket, the plug-in sensor, and the charcoal filter with rubber boot.
Figure 2: CO Detector Component Loca tion
Detector Housing, Housing Cap, & Cap Gasket
The detector housing body protects the sensing components within the housing. Use the
3/4” NPT mounting threads at the top of the housing to screw the CO detector into the
bottom conduit hubs of the junction box. Use t he removable cap near the bottom of the
housing to access the sensor for maintenance or replacement. The cap protects the sensor
from damage and includes a flame arrestor which contains any sparks which may occur
within the detector housing. A cap gasket seals the interface between the housing and cap.
A flame arrestor guard is permanently bonded to the cap.
Two wires extend from the top of the detector housing body. Use these wires to connect
the CO detector to the junction box terminal strip. The housing includes a four-socket
pattern. This socket pattern accepts the sensor’s four pins to secure the sensor within the
detector housing. A pre-amplifier, located between the sockets and two interconnect
wires, conditions the sensor’s signal before the signal reaches the controller.
Plug-In Sensor
The sensor is secured within the sensor housing by four pins. Through a series of chemical
and electrical reactions, the sensor produces an electrical output that corresponds to the
detection range of the detector.
Charcoal Filter
The disc-shaped charcoal filter is secured to the face of the CO sensor with a rubber boot.
The charcoal filter prevents interference gases (hydrogen sulfide [H
hydrocarbons) from producing false CO readings.
S] and certain
2
65-2437RKSS-05 CO D etecto r • 3
Installation
Junction Box
The stainless steel, corrosion resistant junction box allows you to install the detector at a
mounting site that is remote from a controller, and it protects the detector wiring
connections. Two conduit hubs allow you to mount th e detector to the junction box and
connect the wiring from the detector to a controller. An O-ring seals the interface between
the junction box cover and the junction box base.
The terminal block within the junction box facilita tes the wiring process. A cover on the
front of the junction box allows access to the interior of the junction bo x. A lo cking set
screw on the junction box cover allows you to secure the junction box cover and prevent it
from being removed.
This section describes procedures to mount the CO detector in the monitoring
environment and wire the detector to a controller.
Mounting the CO Detector
1.Select a mounting site that is representative of the monitoring environment. Consider
the following when you select the mounting site.
•Select a site where the detector is not likely to be bumped or disturbed. Make sure
there is sufficient room to perform start-up, maintenance, and calibration
procedures.
•Select a site where the target gas is likely to be found first.
NOTE: If your application does not require a specific mounting site, mount the detector
at approximately breathing level.
4 • 65-2437RKSS-05 CO Detector
.20 Dia. x .45
Slot, 2X
3/4 NPT
Female, 2X
3.66
3.15
2.40
Text Oriented
This Way
CO Detector
J-Box
3.34
1.10
8.00 m ax
Figure 3: Outline & Mounting Dimensions
2.At the monitoring site you select, hang or mount the jun c tion box with the detector
facing down (see Figure 3).
Wiring the CO Detector to a Controller
WARNING: Always verify th at the power source is OFF before you make wi ring
connections.
1.Turn off the controller.
2.Turn off or unplug power to the controller.
3.Remove the junction box cover.
WARNING: To maintain the explosion proof classification of the CO detector, a conduit
seal must be used within 18 inches of the junction box conduit hub used for
wiring to the controller.
65-2437RKSS-05 CO D etecto r • 5
4.Guide a two-conductor, shielded cable or two wires in conduit through an unused
Cable Shield
+
CO Detector
Red
Black
Terminal Block
Controller Detector/Transmitter
Terminal s, Typical Designations
Controller Housi ng
S
conduit hub of the junction box. Use appropriate conduit fittings and construction
technique for the environmental and hazardous location rating of the junction box.
The junction box is rated NEMA 4X and Class 1, Division 1, Groups B, C, D.
5.Connect the two wires to the detector using the 2 point terminal block.
CAUTION: If using shielded cable, leave the drain wire insulated and disconnected at th e
detector. You will conn ect the opposite end of the cable’s drain wire at the c ontroller.
6.Secure the junction box cover to the junction box.
7.Route the cable or wires leading from the CO detector through one of the conduit
hubs at the controller housing. Use appropriate conduit fittings and construction
technique for the environmental rating of the controller. RKI controllers are typically
rated NEMA 4X.
CAUTION: Do not route power and detector wiring through the same co nduit hub. The power
cable may disru pt the transmission of the detector signal to the controller.
8.Connect the wires to the applicable controller terminal strip. See the controller
operator’s manual and the controller’s detector head s pecification sheet.
Figure 4: Wiring the CO Detector to a Controller
6 • 65-2437RKSS-05 CO Detector
Start Up
9.If using shielded cable, connect the cable’s drain wire to an available chassis ground at
the controller. RKI controllers typically have a ground stud that is a convenient
grounding location.
10. Reinstall the junction box cover.
This section describes procedures to start up the CO detector and place the detector into
normal operation.
Introducing Incoming Power
1.Complete the installation procedures described earlier in this manual.
2.Verify that the power wiring to the controller is correct and secure. Refer to the
controller operator’s manual.
3.Turn on power to the controller.
4.Turn on the controller.
5.Verify that the controller is on and operating properly. Refer to the controller
operator’s manual.
CAUTION: Allow the detector to warm up for 5 minutes before you continue with the next
section, “Setting t he Zero (Fresh Air) Reading”.
Setting the Zero (Fresh Air) Reading
WARNING: If the detector insta llation is explosion proof, do not remove the detector
housing cap or junction box cover while the circuits are energized unless the
area is determined to be non-hazardous. Keep the detector housing cap and
junction box cover tightly closed during operation.
CAUTION: If you suspect the presence of CO in the monitoring environment, use the calibration
kit and a zero air calibration cylinder to introduce “fresh air” to the CO detector and
verify an accurate zero setting. See “Calibration” on page 12 for instructions to
introduce zero air to the CO detector.
1.Verify that the detector is in a fresh air environment (environment known to be free of
carbon monoxide, other toxic and combustible gases, and of normal oxygen content,
20.9%).
2.Verify a re ading of 0 ppm CO at the contr o ller.
If the display reading is 0 ppm CO, start up is complete. The detector is in normal
operation. If the display reading is not 0 ppm CO, continue with step 3.
3.Perform a zeroing operation at the controller. See the controller operator’s manual for
directions.
65-2437RKSS-05 CO D etecto r • 7
Maintenance
This section describes maintenance procedures. It includes preventive maintenance,
troubleshooting, and component replacement procedures.
Preventive Maintenance
This section describes a preventive maintenance schedule to ensure the optimum
performance of the CO detector. It includes daily, monthly, and qua r terl y proced ures.
Daily
Verify a display reading of 0 PPM CO at the controller. Investigate significant changes in
the display reading.
Monthly
This procedure describes a test to verify that the CO detector responds properly to carbon
monoxide. It describes a test using a fixed flow regulator with an on/off knob. RKI
Instruments, Inc. recommends using a 0.5 LPM (liters per minute) fixed flow regulator.
NOTE: Performing a response test on the CO detector may cause alarms. Be sure to put
the controller into its calibration program or disable external a la r ms before
performing this test.
Preparing for the response test
1.Place the controller into its calibration program or disable external alarms.
2.Verify that the controller display reading fo r the channel you are testing is 0.
If the display reading is not zero, set the zero reading of the detector as described in
the Start Up section of this manual, then continue this procedure.
WARNING: Do not remove the detector housing cap while the circuits are energized
unless the area is determined to be non-hazardous. Keep the detector
housing cap tightly closed duri ng operation.
3.Screw the calibration cup onto the bottom of the CO detector.
4.Screw the regulator into the calibration cylinder.
5.Use the calibration kit sample tubing to connect the regulator to the cali bration cup.
Performing the response test
1.Turn the regulator’s on/off knob counterclockwise to open the regulator. Gas will
begin to flow.
2.Allow the gas to flow for two minutes, then verify that the reading is within ± 20% of
the cylinder gas concentration.
NOTE: If the reading is not within ± 20% of the correct response reading, calibrate the
detector as described in the Calibration section of this manual.
3.Turn the regulator’s on/off knob clockwise to close the regulator.
4.Unscrew the regulator from the calibration cylinder.
5.Unscrew the calibration cup from the CO detector.
8 • 65-2437RKSS-05 CO Detector
6.When the controller display reading falls below the alarm setpoints, return the
controller to normal operation.
7.Store the components of the calibration kit in a safe place.
Quarterly
Calibrate the CO detector as described in the Calibration section of this manual.
Troubleshooting
The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the CO detector.
NOTE: This troubleshooting guide describes detector problems only. See the controller
operator’s manual for problems you may encounter with the controller.
Slow or No
Response/
Difficult or
Unable to
Calibrate
fail condition.
• Detector responds
slowly or does not
respond during
response test.
• Unable to accurately
set the zero or
response reading
during calibration.
• Detector requires
frequent calibration.
Note: Under “normal”
circumstances, the
detector requires
calibration once every 3
months.
Some applications
may require a more
frequent calibration
schedule.
• The detector wiring is
disconnected or
misconnected.
• The plug-in sensor is
not properly plugged
into the sockets in the
detector housing body.
• The detector’s zero
reading is low enough
to cause a fail
condition.
• The detector is
malfunctioning.
• The calibration cylinder
is low, out-dated, or
defective.
• The flame arrestor in
the detector housing
cap is wet or clogged
with dirt or other
particulates.
• The calibration gas is
not an appropriate
concentration.
• The detector is
malfunctioning.
1. Verify that the detector wiring is
correct and secure.
2. Confirm that the plug-in sensor is
installed properly.
3. Perform a zero adjustment. A full
calibration is recommended.
4. If the fail condition continues, replace
the plug-in sensor as described later
in this section.
5. If the fail condition continues, contact
RKI for further instruction.
1. Verify that the calibration cylinder
contains an adequate supply of a
fresh test sample.
2. Check the detector housing cap to
determine if the flame arrestor is wet
or dirty. Clean if necessary.
3. Verify that the calibration gas
concentration is appropriate for the
detector. Zero emission air (20.9%
oxygen) is normally used for a zero
adjustment if the environment is
suspect and 50 PPM CO in air is
normally used for a response
adjustment.
4. If the calibration/response difficulties
continue, replace the plug-in sensor
as described later in this section.
5. If the calibration/response difficulties
continue, contact RKI for further
instruction.
Unexplained
Upscale
Readings or
Alarms
• Controller indicates a
CO reading that
cannot be verified.
• CO alarms occur at
the controller that
cannot be explained.
• Charcoal filter is
saturated and no
longer scrubbing out
interfering gases.
1. Replace charcoal filter.
2. If difficulties continue, contact RKI for
further instructions.
65-2437RKSS-05 CO D etecto r • 9
Replacing Components of the CO Detector
This section includes a procedure to replace the CO sensor, the charcoal filter, and the
entire detector assembly. In most cases, it is not necessary to replace the entire detector
assembly.
Replacing the Plug-In CO Sensor
CAUTION: The sensor contains electrolyte which is a dilute acid. Do not disassemble the sensor
when replacing it with a new one. If sensor electrolyte comes in contac t with your
skin, wash affected area thoroughly with soap and water.
1.Turn off the controller.
2.Turn off or unplug power to the controller.
3.Unscrew the detector housing cap from the detector housing body. Make sure not to
lose the cap gasket.
4.Unplug and remove th e CO sensor wit h the boot and charcoal filter attached
5.Remove the rubber boot and charcoal filter from the old sensor.
6.Install the rubber boot with charcoal filter onto the replacement sensor’s face.
7.Carefully plug the replacement sensor into the four-socket pattern that is located in
the detector housing.
8.Make sure the cap gasket is in place and screw the detector housing cap back onto the
detector housing body.
9.Turn on or plug in power to the controller.
10. Turn on the controller and place into normal operation.
CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue with the
next step.
11. Calibrate the replacement sensor as described in the Calibration section of this
manual.
Replacing the Charcoal Filter
1.Turn off the controller.
2.Turn off or unplug power to the controller.
3.Unscrew the detector housing cap from the detector housing body.
4.Unplug and remove th e CO sensor wit h the boot and charcoal filter attached.
5.Remove the rubber boot that secures the charcoal filter to the CO sensor.
6.Remove the charcoal filter from the rubber boot.
7.Place the replacement filter in the rubber boot in the same position as the filter you
removed in the previous step.
8.Reinstall the rubber boot with charcoal filter to the CO sensor.
9.Carefully plug the replacement sensor into the four-socket pattern that is located in
the detector housing.
10. Make sure the cap gasket is in place and screw the detector housing cap back onto the
detector housing body.
10 • 65-2437RKSS-05 CO Detector
11. Turn on or plug in power to the controller.
12. Turn on the controller and place into normal operation.
Replacing the CO Detector
NOTE: In most cases, it is only necessary to replace the CO sensor.
1.Turn off the controller.
2.Turn off or unplug power to the controller.
3.Remove the junction box cover.
4.Disconnect the detector leads from the terminal block in the junction box. Note the
position of the color-coded leads as you remove them.
5.Unscrew the detec tor from the junction box hub.
6.Guide the detector leads of the replacement detector through the junction box hub
then screw the mounting threads of the detector into the hub.
7.Connect the detector leads to the terminal block the same way the old detector was
wired. See the controller operator’s manual and the controller’s detector head
specification sheet to verify the connections are correct.
8.Reinstall t he junction box cover.
9.Turn on or plug in power to the controller.
10. Turn on the controller and place into normal operation.
CAUTION: Allow the replacement detector to warm up for 5 minutes bef o r e yo u c o ntinue with
the next step.
11. Calibrate the replacement detector as described in the Calibration section of this
manual.
Calibration Frequency
Although there is no particular calibration frequency that is correct for all applica tions, a
calibration freq uency of every 3 months is adequate for most CO detector applications.
Unless experience in a particular application dictates otherwise, RKI In struments, Inc.
recommends a calibration frequency of every 3 months for the CO detector.
If an application is not very demanding, for example detection in a clean, temperature
controlled environment, and calibration adju stments are minimal at calibration, then a
calibration freque ncy 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.
65-2437RKSS-05 CO D ete ctor • 11
Calibration
This section describes how to calibrate the CO detector. It includes procedures to prepare
for calibration, set the zero reading, set the response reading, and return to normal
operation. It describes calibration using a calibration kit that includes a calibration cup,
calibration gas, sample tubing, and a fixed flow regulator with an on/off knob. RKI
Instruments, Inc. recommends using a 0.5 LPM (liters per minute) fixed flow regulator.
Preparing for Calibration
NOTE: Calibrating the CO detector may cause alarms. Be sure to put the controller into
its calibration program or disable external alarms before calibrating.
WARNING: Do not remove the detector housing cap while the circuits are energized
unless the area is determined to be non-hazardous. Keep the detector
housing cap tightly closed duri ng operation.
1.Screw the calibration cup onto the bottom of the CO detector.
2.Screw the regulator into the zero air calibration cylinder.
3.Use the calibration kit sample tubing to connect the fixed flow regulator to the
calibration cup.
4.Put the controller into its calibration program.
Setting the Zero Reading
NOTE: If you can verify that the CO detector is in a fresh air environment, you do not
need to apply zero air to the detector before adjusting the zero reading.
1.Follow the directions in the cont roller operator’s manual for setting the zero reading.
2.When the instructions call for applyin g zero air to the detector, turn the regulator’s
on/off knob counterclockwise to open it .
3.Allow the gas to flow for two minutes.
4.Set the zero reading according to the controller operator’s manual.
5.Turn the regulator’s on/off knob clo ckwise to close it.
6.Unscrew the regulator from the zero air calibration cylinder.
7.Leave the sample tubing connected to the regulator and the calibration cup.
NOTE: Depending on the size of your zero air cylinder, it is possible that you will have a
different regulator for the zero air cylinder and the CO gas cylinder. If necessary
to fit the CO calibration gas cylinder, change the regulator.
Setting the Response Reading
1.Screw the regulator into the calibration gas cylinder.
2.Follow the directions in the controller operator’s manual for setting the response
reading (span).
12 • 65-2437RKSS-05 CO Detector
3.When the directions call for exposing the detector to gas, turn the regula tor’s on/off
knob counterclockwise to open it.
4.Allow gas to flow for 2 minutes.
5.Set the response reading according to the controller operator’s manual.
6.After setting the response reading, turn the regulator’s on/off knob clockwise to close
it.
7.Unscrew the regulator from the cylinder.
8.Remove the calibration cup from the detector.
NOTE: For convenience, leave regulator and calibration cup connected by the sample
tubing.
9.Allow about 45 seconds for the gas reading to decrease below the alarm points and
then return the controller to normal operation.
NOTE: If you do not allow the gas reading to decrease below the alarm points, then
unwanted alarms may occur.
10. Verify that the cont roller d isplay reading decreases and stabilizes at 0 ppm CO.
11. Store the components of the calibration kit in a sa fe a nd convenient place.
65-2437RKSS-05 CO D ete ctor • 13
Parts List
Table 5 lists replacement parts and accessories for the CO detector.
Table 3: Parts List
Part NumberDescription
06-1248RKSample tubing (order by the foot)
07-0033RKDetector housing cap gasket
07-0203RKRubber retaining boot (for charcoal filter)
07-7151RKO-ring for junction box
10-5153RKLid locking set screw for junction box
18-0416RK-11Junction box with cover, stainles s ste e l
33-7101RKCharcoal filter disk
65-2437RKSS-05CO detector/j-box, CSA classified
65-2438CO detector (with plug-in sensor)
71-043965-2437RKSS-05 CO Detector Ope rator’s Manual (this document)
81-0064RKCalibration cylinder, 50 PPM CO in air, 17 liter
81-0064RK-01Calibration cylinder, 50 PPM CO in air, 34 liter steel
81-0064RK-03Calibration cylinder, 50 PPM CO in air, 103 liter
81-0076RKZero air cal ibration cylinder, 17 liter
81-0076RK-01Zero air calibration cylinder, 34 liter steel
81-0076RK-03Zero air calibration cylinde r, 103 liter
81-1050RKRegulator with gauge and knob, 0.5 LPM, for 17 liter and 34 liter steel
calibration cylinders (cylinders with external threads)
81-1051RKRegulator with gauge and knob, 0.5 LPM, for 34 liter aluminum, 58
liter, and 103 liter calibration cylinders (cylinders with internal threads)
81-1117RKCalibration cup
ES-1531-COCO replacement sensor
14 • 65-2437RKSS-05 CO Detector
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