Read and understand this instruction manual before operating
instrument. Improper use of the gas monitor could result in
bodily harm or death.
Periodic calibration and maintenance of the gas monitor is
essential for proper operation and correct readings. Please calibrate and maintain this instrument 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.
65-2433RK-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 fr o m date of shipment
from RKI Instruments, Inc. Any parts found defective withi n tha t 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 ser v ice, and
which must be cleaned, repaired, or replaced on a routine basis. Examples of such items
are:
W arranty 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 , a nd we are not r esponsible for removal or r eplacement costs,
local repair costs, transportation costs, or contingent expenses incurred without 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. 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 no t as su me indemnif ic a t ion for any accident or d amage caused b y t he op e r a t ion of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.
This manual describes the 65-2433RK-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 thi s instruction
manual.
Table 1 lists specifications for the CO Detector.
Table 1: Specifications
Target GasCarbon monoxi de (CO)
Area Classification*Explosionproof for Class I, Groups B, C, and D
Temperature CodeT6
Installation CategoryInstallation Category 1. Signal level, special equipm ent or parts of
Sampling MethodDiffusion
Signal Output4 to 20 mA
Detection Range0 to 100 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)
* This area classification only applies if the detector is installed using a Killark HKB junction box and a
Killark HFC, HK2D, or HK4D cover.
NOTE: The following symbol on the detector label is a caution to the user to refer to this
documentation for installation and operation instructions:
equipment, telecommunication, electronic, etc., with smaller
transient overvoltages than Installati on Category (Overvoltage
Category) II (ref. IEC 664).
2.5 mA at 300 ppm CO nominal
WARNING: When using the 65-2433RK-05, you must follow the instructions and
warnings in this manual to assure proper and safe opera tion of the
65-2433RK-05 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 65-2433RK-05 as described in this
manual.
65-2433RK-05 CO D et ec t or • 1
Description
This secti on describe s t he c omponents of t he CO detector. The detector consists of the CO
sensor, charcoal filter with rubber boot, detector housing body, detector housing cap, and
cap gasket.
Detector Housing Body
Cap Gasket
Plug-In CO Sensor
Rubber Boot With
Charcoal Filter
Detector Housing Cap
Flame Arrestor
Guard
Figure 1: 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 the 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 a controller. 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 co ntroller.
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
2 • 65-2433RK-05 CO Detector
Installation
This section describes procedures to mount the CO detector in th e 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. Ma ke sur e
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.
Shrink Tubing
3/4 NPT
0.75
3.48
Ø 1.75
1-1/2 20 Thread for
Calibration Cup
Figure 2: Outline & Mounting Dimensions
2.At the monitoring site, install the detector in the bottom conduit hub of a junction box:
CAUTION: Mount the C O detector with the detector facin g down (see Figure 2).
65-2433RK-05 CO D et ec t or • 3
NOTE: If the mounting site requires the detector installation to be explosion proof, you
must install the detector in a Killark HKB junction box with a Killark HF C,
HK2D, or HK4D cover.
Wiring the CO Detector to a Controller
WARNING: Always verify that the power source is OFF bef ore you make wiring
connections.
1.Turn off the controller.
2.Turn off or unplug p ower to the controller.
3.Remove the junction box cover.
WARNING: To maintain the explosi on proof classification of the CO detector/junction
box combination, a conduit seal must be used within 18 inches of the
junction box conduit hub used for wir ing to the controller.
4.Guide a two-conductor, shielded cable or two wires in conduit through an unused
conduit hub of the junction box.
5.Connect the two wires to the detector using an appropriate terminal block.
CAUTION: If using shielded cable, leave the drain wire insulated and disconne cted at the
detector. You will connect the opposite end of th e cable’s drain wire at the controller.
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.
CAUTION: Do not route power and detector wiring through the same conduit hub. The power
cable may disru pt the transmission of the detect or 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 specification sheet.
4 • 65-2433RK-05 CO Detector
Controller Detector Terminals,
Typical Des ignations
Co ntroller Housing
+
S
ShieldedCable
Terminal Strip
CO Detector
Black
Junction
Box
Red
Figure 3: Wiring the CO Detector to a Controller
9.Connect the cable’s dr ain wire to an available chassis ground at the controller.
10. Reinstall the junction box cover.
65-2433RK-05 CO D et ec t or • 5
Start Up
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.Tu rn 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 ma nual.
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 installation is expl osi on 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 de tector and
verify an accurate zero setting. See “Calibration” on page 10 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 readin g of 0 ppm CO at the controller.
If the display reading is 0 ppm CO, start up is complete. The detector is in n orm al
operation. If the display reading is not 0 ppm CO, continue with step 3.
3.Perform a zeroing operation at the controller. See the contr oller operato r’s manual for
directions.
6 • 65-2433RK-05 CO Detector
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 quarterly procedures.
Daily
Verify a disp lay 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 alarms before
performing this test.
Preparing for the response test
1. Place the controller into its calibration program or disable external alarms.
2.Verify tha t the controller display reading for 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 calibration 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 ± 10% of
the cylinder gas concentration.
NOTE: If the reading is not within ± 10% 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 cylind er.
5.Unscrew the calibration cup from the CO detector.
65-2433RK-05 CO D et ec t or • 7
6.When the controller display reading falls below th e 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 reco mmended
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 encounte r with the controller.
Slow or No
Response/
Difficult or
Unable to
Calibrate
fail condition.
• Detector responds
slowly or does not
respond to response
test.
• Unable to accurately
set the zero or
response reading
during calibration.
• Detector requires
frequent calibration.
Note: Under “normal”
circumstances, the
transmitter 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 appr opriate
concentration.
• The detector is
malfunctioning.
1. Verify that the detector wiring is
correct and secure.
2. Confirm that the plug-in sensor is
installed properl y.
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
transmitter. 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
8 • 65-2433RK-05 CO Detector
• 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 char co al filter.
2. If difficulties continue, contact RKI for
further instructions.
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 dis assemble the sens o r
when replacing it with a new one. If sensor electrolyte comes in co ntact with your
skin, wash affected area thoroughly with soap and water.
1.Turn off the controller.
2.Turn off or unplug p ower 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 the CO sensor with 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 r ep la cem ent sens or to w arm up for 5 m inu tes 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 p ower to the controller.
3.Unscrew the detector housing cap from the detector housing body.
4.Unplug and remove the CO sensor with 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.
65-2433RK-05 CO D et ec t or • 9
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 p ower 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 detector from the junction box hub.
6. Gu ide 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 the 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 before y o 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 applications, a
calibration frequency of every 3 months is adequate for most CO detector applications.
Unless experience in a particular application dictates otherwise, RKI Instruments, 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 adjustments a re minima l 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 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.
10 • 65-2433RK-05 CO Detect or
Prepari ng for Ca libration
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 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 controller operator’s manual for setting the zero reading.
2.When the instructions call for applying z e ro 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 clockwise to close it.
6.Leave the sample tubing connected to the regulator and the calibration cup.
Setting the Response Reading
1.Follow the directions in the controller operator’s manual for setting the response
reading (span).
2.When the directions call for exposing the detector to gas, turn the regulator’s on/off
knob counterclockwise to open it.
3.Allow gas to flow for 2 minutes before continuing with the directions.
4.After setting the response reading, turn the regulator’s on/off knob clockwise to close
it.
5.Unscrew the regulator from the cylinder.
6. Remove the calibration cup from the detector.
NOTE: For convenience, leave regulator and calibration cup connected by the sample
tubing.
7. Allow about 45 seconds for the gas reading to decrease below the alarm points and
then return the controller to normal operation.
65-2433RK-05 CO De t ec to r • 1 1
Parts List
NOTE: If you do not allow the gas reading to decrease below the alarm points, then
unwanted alarms may occur.
8.Verify that the controller display reading decreases and stabilizes at 0 ppm CO.
9.Store the components of the calibration kit in a safe and convenient place.
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 cha rcoal filter)
33-7101RKCharcoal Filter Disk
65-2433RK-05CO replacement detector assemb ly (includes sensor)
71-0189RK65-2433RK-05 CO Detector Operator’s Manual (this document)
81-0064RK-01Calibration cylinder, 50 PPM CO in air, 34 liter steel
81-0064RK-03Calibration cylinder, 50 PPM CO in air, 103 liter steel
81-0076RKZero air calibration cylinder, 17 liter steel
81-0076RK-01Zero air calibration cylinder, 34 liter steel
81-0076RK -03Zero air calibration cylinder, 103 liter steel
81-1050RKRegulator with gauge and knob, 0.5 LPM, for 17 liter an d 34 liter
steel calibration cylinders
81-1051RKRegulator with gauge and knob, 0.5 LPM , for 34AL/58/103 liter
calibration cylinders
81-1117RKCalibration cup
ES-1531-COCO replacement sensor
12 • 65-2433RK-05 CO Detect or
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