RKI Instruments 61-1004RK User manual

www.rkiinstruments.com
61-1004RK/61-0191RK
CO2Detector
Operator’s Manual
Part Number: 71-0145RK
Revision: P1
Released: 7/10/07

2 • 61-1004RK/61-0191RK Combustible Gas Detector
Product Warranty
RKI Instruments, Inc., warrants gas alarm equipment sold by us to be free from defects in
materials, workmanship, and performance for a period of one year from date of shipment
from RKI Instruments, Inc. Any parts found defective within that period will be repaired
or replaced, at our option, free of charge. This warranty does not apply to those items
which by their nature are subject to deterioration or consumption in normal service, and
which must be cleaned, repaired, or replaced on a routine basis. Examples of such items
are:
Warranty is voided by abuse including mechanical damage, alteration, rough handling, or
repair procedures not in accordance with the operator’s manual. This warranty indicates
the full extent of our liability, and we are not responsible for removal or replacement costs,
local repair costs, transportation costs, or contingent expenses incurred without our prior
approval.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER
WARRANTIES AND REPRESENTATIONS, EXPRESSED OR IMPLIED,
AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF
RKI INSTRUMENTS, INC., INCLUDING BUT NOT LIMITED TO, THE
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS,
INC., BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL
LOSS OR DAMAGE OF ANY KIND CONNECTED WITH THE USE OF
ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR
OPERATE PROPERLY.
This warranty covers instruments and parts sold to users by authorized distributors,
dealers, and representatives as appointed by RKI Instruments, Inc.
We do not assume indemnification for any accident or damage caused by the operation of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.
a) Absorbent cartridges d) Batteries
b) Pump diaphragms and valves e) Filter elements
c) Fuses

61-1004RK/61-0191RK Combustible Gas Detector • 3
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IR CO2Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting the CO2Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring the CO2Detector to a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Startup
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Confirming the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacing the CO2Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembling the Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 • 61-1004RK/61-0191RK Combustible Gas Detector
Overview
This manual describes the 65-1004RK CO2(carbon dioxide) detector. This manual also
describes how to install, start up, maintain, and calibrate the detector when used with a
gas monitoring controller. A parts list at the end of this manual lists replacement parts and
accessories for the CO2detector.
The 61-1004RK CO2detector includes a junction box. This manual may also be used for
the 61-0191RK CO2detector which does not include a junction box and is normally
mounted in one of a controller’s conduit hubs and factory wired to the controller. If you
are using a 61-0191RK CO2detector, disregard all references to the junction box and
junction box terminal block.
Specifications
Table 1 lists specifications for the CO2detector.
Table 1: 61-1004RK Specifications
Detection Range With Junction Box
61-1004RK-02: 0 - 5,000 ppm CO2
61-1004RK--03: 0 - 5% volume CO2
Without Junction Box
61-0191RK-02: 0 - 5,000 ppm CO2
61-0191RK-03: 0 - 5% volume CO2
Area Classification Explosionproof for Class I, Groups B, C, and D
Sampling Method Diffusion
Response Time 90% in 45 seconds

61-1004RK/61-0191RK Combustible Gas Detector • 5
Description
The 61-1004RK CO2detector has two versions, the 61-1004RK-02 which has a detection
range of 0 - 5,000 ppm and the 61-1004RK-03 which has a detection range of 0 - 5%
volume. The detector is an infrared type of detector. This section describes the
components of the 61-1004RK. They include the infrared CO2detector and the junction
box.
Infrared CO2Detector
The infrared CO2detector is made up of a miniature infrared CO2detector housed and
encapsulated in a pipe nipple. The pipe nipple has 3/4 inch NPT threads on each end and
a 1-1/4 inch hex that allows removal or installation of the detector with a wrench. A
porous flame arrestor coated with a hydrophobic film that repels liquids is on one end of
the detector and allows sample gas to enter the detector. Four color coded leads, red,
white, green, and black, extend from the other end of the detector. The leads allow you to
connect the detector to the terminal block in the junction box.
To distinguish the 5,000 ppm detector from the 5% detector (in case the replacement
detector label that is applied to one of the leads is lost), a short length of black shrink
tubing is applied to the white wire of the 5,000 ppm detector near where the wire comes
out of the nipple and a short length of green shrink tubing is applied to the white wire of
the 5% detector.
The output of the CO2detector mimics the output of RKI’s standard catalytic LEL
detectors. For this reason, the CO2 detector’s wire colors are the same as RKI’s catalytic
LEL detectors, black, white, green, and red. When the CO2detector is wired to an RKI
controller, it is wired the same way an LEL detector is wired, to the LEL detector
terminals. See “Wiring the CO2 Detector to a Controller” on page 6 for wiring
connections.
Junction Box
The 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 3/4” NPT conduit hubs
allow you to mount the detector to the junction box and connect the wiring from the
detector to a controller. The terminal block within the junction box facilitates the wiring to
the detector. A cover on the front of the junction box allows access to the interior of the
junction box. Three spacers installed on the back of the junction box control the distance of
the junction box from a mounting surface and insure that there is enough room to install a
calibration cup on the detector during calibration.

6 • 61-1004RK/61-0191RK Combustible Gas Detector
Installation
This section describes procedures to mount the CO2detector in the monitoring
environment and wire the it to a controller. If you purchased a 61-0191RK detector that is
factory installed in and factory wired to a controller, detector installation is not necessary.
Mounting the CO2Detector
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.
• Select a site that minimizes the possibility of someone breathing on the detector.
The exhaled CO2may cause an alarm.
Figure 1: Mounting the CO2Detector
2. At the mounting site you select, hang or mount the junction box with the detector
facing down (see Figure 1).
Wiring the CO2Detector to a Controller
WARNING: Always verify that the power to the controller is off before you make
wiring connections.
Junction
Box
Spacer, 3X
IR CO2
Detector
3/4 NPT
Female
3.65
7.1 Max
2.70 0.38

61-1004RK/61-0191RK Combustible Gas Detector • 7
As mentioned in “Infrared CO2 Detector” on page 5, the IR CO2detector wires to an RKI
controller the same way as an RKI LEL detector, to the LEL detector terminals. See
Figure 2 below for the wiring connections.
1. Turn off the controller.
2. Turn off or unplug power to the controller.
3. Remove the cover from the junction box.
4. Guide a four-conductor, shielded cable or four wires in conduit through the top
conduit hub of the junction box. Connect the wires to the terminals opposite the
detector leads.
CAUTION: Leave the shield drain wire insulated and disconnected at the 61-1004RK. You will
connect the opposite end of the cable’s drain wire at the controller.
5. Secure the junction box cover to the junction box.
6. Route the cable or wires in conduit leading from the detector through one of the
conduit hubs at the controller.
CAUTION: Do not route power and detector wiring through the same conduit hub. The power
cable may disrupt the transmission of the detector signal to the controller.
Figure 2: Wiring the CO2Detector to a Controller
Black
Green
White
Red
Terminal Strip
Black
Green
White
Red
IR CO2
Detector
Controller
LEL Detector
Terminals
Detector
Wires
Cable Shield
Controller Housing

8 • 61-1004RK/61-0191RK Combustible Gas Detector
Start Up
This section describes procedures to start up the CO2detector 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 or plug in power to the controller, then turn on the controller.
4. 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, “Confirming the Zero Reading.”
Confirming the Zero Reading
There is typically between 200 ppm and 400 ppm CO2in air depending on the geographic
location, so it is necessary to apply a CO2free gas to the CO2detector when setting the
zero reading.
The procedure below describes applying 100% nitrogen to the detector using a calibration
kit that includes a calibration cup, a calibration cylinder of 100% nitrogen, sample tubing,
and a 0.5 LPM (liters per minute) fixed flow regulator with an on/off knob.
1. Screw the calibration cup onto the bottom of the CO2detector.
2. Screw the regulator into the 100% nitrogen calibration cylinder.
3. Use the sample tubing to connect the regulator to the calibration cup.
4. Turn the regulator’s on/off knob counterclockwise to open it. Gas will begin to flow.
5. Allow the gas to flow for one minute.
6. Verify a reading of 0% CO2or 0 ppm CO2depending on the detector you are
calibrating at the controller.
If the display reading is 0, the CO2detector is in normal operation and start up is
complete. Proceed to step 7 to disassemble the calibration kit.
If the display reading is not 0, turn the regulator’s on/off knob clockwise to close it,
then proceed to “Setting the Zero Reading” on page 12 to set the zero reading.
7. Turn the regulator’s on/off knob clockwise to close it.
8. Unscrew the cylinder from the regulator and remove the sample tubing from the
regulator.
9. Remove the calibration cup from the detector. You may leave the sample tubing
connected to the calibration cup for convenience.
10. Store the components of the calibration kit in a safe and convenient place.

61-1004RK/61-0191RK Combustible Gas Detector • 9
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 CO2detector. It includes daily, monthly, and biannual procedures.
Daily
Verify a display reading of around 200 ppm to 400 ppm (0.02% to 0.04%) CO2at the
controller. Investigate significant changes in the reading.
Monthly
This procedure describes a test to verify that the CO2detector responds properly to the
target gas.
WARNING: The controller is not an active gas monitoring device during the response
test procedure.
NOTE: Performing a response test on the CO2detector may cause alarms. Be sure to put
the controller into its calibration program or disable external alarms before
performing this test
The procedure below describes applying CO2to the detector using a calibration kit that
includes a calibration cup, a CO2calibration gas cylinder, sample tubing, and a 0.5 LPM
(liters per minute) fixed flow regulator with an on/off knob.
1. Place the controller into its calibration program or disable external alarms.
2. Verify that the controller display reading is around 200 ppm to 400 ppm (0.02% to
0.04%) CO2.
If the reading is significantly out of this range, set the zero reading then continue this
procedure. See“Setting the Zero Reading” on page 12 to set the zero reading.
3. Screw the calibration cup onto the detector.
4. Use the sample tubing to connect the regulator to the calibration cup.
5. Screw the regulator into the calibration cylinder.
6. Turn the on/off knob on the regulator counterclockwise to open the regulator.
7. Apply gas to the detector for one minute.
8. Verify that the reading is within ± 20% of the gas concentration.
NOTE: If the reading is not within ± 20% of the gas concentration, calibrate the detector
as described in “Calibration” on page 11.
9. Turn the on/off knob clockwise to close the regulator.
10. Unscrew the regulator from the calibration cylinder and remove the sample tubing
from the regulator.

10 • 61-1004RK/61-0191RK Combustible Gas Detector
11. Unscrew the calibration cup from the detector. You may leave the sample tubing
connected to the calibration cup for convenience.
12. When the display reading falls below the alarm setpoints, return the controller to
normal operation or enable external alarms.
13. Store the components of the calibration kit in a safe place.
Biannually
Calibrate the CO2detector every six months as described in “Calibration” on page 11.
Troubleshooting
The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the CO2detector.
NOTE: This troubleshooting guide describes detector problems only. See the controller
operator’s manual for problems you may encounter with the controller.
Replacing the CO2Detector
1. Turn off the controller.
2. Turn off power to the controller.
3. Remove the junction box cover.
Table 2:Troubleshooting the CO2Detector
Condition Symptom(s) Probable Causes Recommended Action
Fail Condition • Controller indicates a
fail condition. • The detector wiring is disconnected or
misconnected.
• The detector zero
signal is low enough to
cause a fail condition.
• The detector is
malfunctioning.
1. Verify that the detector wiring is
correct and secure.
2. Calibrate the detector.
3. If the fail condition continues, replace
the detector.
4. If the fail condition continues, contact
RKI for further instruction.
Slow or No
Response/
Difficult or
Unable to
Calibrate
• 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
detector requires
calibration once every
six months.
Some applications may
require a more frequent
calibration schedule.
• Thecalibrationcylinder
is low, out-dated, or
defective.
• The regulator flow rate
is not 0.5 LPM
• The detector is
malfunctioning.
1. Verify that the calibration cylinder
contains an adequate supply of a
fresh test sample.
2. Confirm that the regulator being used
is a 0.5 LPM regulator.
3. If the calibration/response difficulties
continue, replace the detector.
4. If the calibration/response difficulties
continue, contact RKI for further
instruction.

61-1004RK/61-0191RK Combustible Gas Detector • 11
4. Disconnect the detector leads from the terminal block inside the junction box. Note
the position of the color-coded leads as you remove them.
5. Unscrew the detector from the junction box.
6. Guide the detector leads of the replacement detector through the bottom conduit hub
of the junction box, then screw the mounting threads of the detector into the conduit
hub.
7. Connect the detector leads to the terminal block in the same position as the leads you
removed in step 4.
8. Secure the junction box cover to the junction box.
9. Turn on power to the controller.
10. Turn on the controller.
11. Calibrate the replacement detector as described in“Calibration” on page 11.
Calibration Frequency
Although there is no particular calibration frequency that is correct for all applications, a
calibration frequency of every 6 months is adequate for most infrared CO2detector
applications. Unless experience in a particular application dictates otherwise, RKI
Instruments, Inc. recommends a calibration frequency of every 6 months for the infrared
CO2detector.
If an application is not very demanding, for example detection in a clean, temperature
controlled environment where CO2is not normally present, and calibration adjustments
are minimal at calibration, then a calibration frequency of every 9 to 12 months is
adequate.
If an application is very demanding, for example if the environment is not well controlled,
then more frequent calibration than every 6 months may be necessary.
Calibration
This section describes how to calibrate the CO2detector. It includes procedures to
assemble the calibration kit, set the zero reading, set the response reading and return to
normal operation.
WARNING: The controller is not an active gas monitoring device during the calibration
procedure.
The following procedure assumes the use of a calibration kit which includes a 100%
nitrogen calibration gas cylinder for setting the zero, a CO2calibration gas cylinder for
setting the response reading, a 0.5 LPM fixed flow regulator with an on/off knob, a
calibration cup for the detector, and a short piece of sample tubing to connect the
regulator to the calibration cup.
Assembling the Calibration Kit
1. Screw the calibration cup onto the detector.
2. Use the sample tubing to connect the regulator to the calibration cup.
3. Place the controller into its calibration program or disable external alarms.

61-1004RK/61-0191RK Combustible Gas Detector • 12
NOTE: Calibrating the CO2detector may cause alarms. Be sure to put the controller into
its calibration program or disable external alarms before continuing.
Setting the Zero Reading
1. Follow the directions in the controller’s operator’s manual for setting the zero reading
(sometimes called the fresh air reading).
2. When the directions call for exposing the detector to zeroing gas, screw the regulator
into the cylinder, turn the on/off knob counterclockwise to open the regulator, and
allow the gas to flow to the detector for 1 minute before continuing with the
directions.
3. After setting the zero reading, turn the regulator’s on/off knob clockwise to close the
regulator.
4. Unscrew the 100% nitrogen cylinder from the regulator.
Setting the Response Reading
1. Follow the directions in the controller’s operator’s manual for setting the response
reading (span).
2. When the directions call for exposing the detector to calibration gas, screw the CO2
cylinder onto the regulator, turn the on/off knob counterclockwise to open the
regulator, and allow the gas to flow to the detector for 1 minute before continuing
with the directions.
3. After setting the response reading, turn the regulator’s on/off knob clockwise to close
the regulator.
4. Unscrew the CO2cylinder from the regulator.
5. Remove the sample tubing from the regulator.
6. Remove the calibration cup from the detector. Leave the sample tubing connected to
the calibration cup for convenience.
7. Allow the reading at the controller to decrease below the alarm points before
returning the controller to normal operation or enabling external alarms.
NOTE: If you do not allow the gas reading decrease below the alarm points, then
unwanted alarms may occur.
8. Verify that the controller display reading decreases and stabilizes at 0.
9. Store the components of the calibration kit in a safe and convenient place.

61-1004RK/61-0191RK Combustible Gas Detector • 13
Parts List
Table 3 lists replacement parts and accessories for the 61-1004RK and 61-0191RK CO2
detectors.
Table 3: Parts List
Part Number Description
18-0400RK-01 Junction box with spacers
61-0191RK-02 0 to 5,000 ppm CO2infrared detector
61-0191RK-03 0 to 5% volume CO2infrared detector
71-0145RK 61-1004RK/61-0191RK CO2Detector Operator’s Manual (this
document)
81-0070RK-01 Calibration cylinder (2,000 ppm CO2 in nitrogen, 34 liter)
81-0072RK-01 Calibration cylinder (2.5% CO2 in nitrogen, 34 liter)
81-0078RK-01 100% nitrogen calibration cylinder (34 liter)
81-1050RK Regulator, 0.5 liter/minute, with gauge and knob, for 17- and 34-
liter calibration cylinders
81-1103RK Calibration cup
81-F403RK-LV Calibration kit, for 3/4” NPT detector, 2.5% CO2, 34 liter
81-F404RK-LV Calibration kit, for 3/4” NPT detector, 2,000 ppm CO2, 34 liter