RKI Instruments 65-2396RK 04 Series User manual

RKI Instruments, Inc.
www.rkiinstruments.com
65-2396RK-XX-04
CO2Transmitter
Operator’s Manual
Part Number: 71-0656
Revision: P1
Released: 1/16/24

2• 65-2396RK-XX-04 CO2Transmitter Operator’s Manual
WARNING
Read and understand this instruction manual before operating
transmitter. Improper use of the transmitter could result in bodily
harm or death.
Periodic calibration and maintenance of the transmitter is essential for
proper operation and correct readings. Please calibrate and maintain
this transmitter regularly! Frequency of calibration depends upon the
type of use you have and the sensor types. Typical calibration
frequencies for most applications are between 9 and 12 months, but
can be required more often or less often based on your usage.

65-2396RK-XX-04 CO2Transmitter Operator’s Manual • 3
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:
• Absorbent cartridges
•Fuses
• Pump diaphragms and valves
•Batteries
• Filter elements
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 APARTICULAR PURPOSE. INNO
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.

4• 65-2396RK-XX-04 CO2Transmitter Operator’s Manual
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CO2Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Amplifier Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Detector Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting the CO2Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wiring the Detector to the Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wiring the Amplifier to a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Setting the Zero Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing Components of the CO2Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

65-2396RK-XX-04 CO2Transmitter Operator’s Manual Overview • 5
Overview
This manual describes the 65-2396RK-XX-04 CO2transmitter. This manual also describes how
to install, start up, configure, maintain, and calibrate the transmitter 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 CO2transmitter.
Specifications
Table 1 lists specifications for the 65-2396RK-XX-04 CO2transmitter.
WARNING: When using the 65-2396RK-XX-04, you must follow the instructions and
warnings in this manual to assure proper and safe operation of the 65-2396RK-
XX-04 and to minimize the risk of personal injury. Be sure to maintain and
periodically calibrate the 65-2396RK-XX-04 as described in this manual.
Table 1: Specifications
Target Gas Carbon Dioxide (CO2)
Area Classification Explosion-proof for Class I, Groups B, C, and D
Sampling Method Diffusion
Signal Output 4 to 20 mA
Detection Range
65-2396RK-01-04: 0-9,000 ppm
65-2396RK-02-04: 0-5,000 ppm
65-2396RK-03-04: 0-5% volume (vol.)
65-2396RK-04-04: 0-20% vol.
65-2396RK-05-04: 0-50% vol.
65-2396RK-10-04: 0-100% vol.
Response Time 90% in 45 seconds
Operating Temperature -4°F to 122°F (-20°C to 50°C)
Accuracy ± 5% of reading or ± 2% of full scale (whichever is greater)

6• Description 65-2396RK-XX-04 CO2Transmitter Operator’s Manual
Description
This section describes the components of the CO2transmitter. The transmitter is a 4 - 20 mA type
detector head. It consists of the CO2detector, amplifier, the amplifier junction box, and the
detector junction box. The two-junction-box configuration is intended for situations where the
detector needs to be installed at an inaccessible location. The detector junction box can be
installed at the inaccessible location and the amplifier junction box can be installed in a more
readily accessible area.
Figure 1: CO2Transmitter Component Location
IR CO2 Detector
Amplifier J-Box
Detector Terminal
Strip
Controller Terminal Strip
Amplifier
Red
Calibration
Cup/Splash
Guard
PWR / SIG
B
ZERO
S
LEL
G
R
Sensor
Current
mA
W
SPAN
White
Green Detector J-Box
Black

65-2396RK-XX-04 CO2Transmitter Operator’s Manual Description • 7
Infrared CO2Detector
The CO2detector is made up of a miniature infrared CO2detector housed and encapsulated in a
pipe nipple. The pipe nipple has 3/4 NPT threads on each end and a 1 1/4” hex that allows
removal or installation of the detector with a wrench. A porous flame arrestor that is 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 amplifier.
To distinguish the different ranges of CO2detectors from one another, a short length of shrink
tubing is applied to the wiring where it comes out of the nipple. The following table indicates the
color of the shrink tubing and the color of the wire to which it is applied.
The output of the CO2detector mimics the output of RKI’s standard catalytic LEL detectors. For
this reason, the CO2detector’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 Detector to the
Amplifier” on page 11 for wiring connections.
Calibration Cup/Splash Guard
A calibration cup/splash guard is installed on the IR CO2detector. A fitting at the bottom of the
calibration cup/splash guard allows a length of tubing to be connected for calibration and routed
to a more easily accessible location. The calibration cup/splash guard also protects the detector.
Table 2: Detector Color Designations
Detector Range Shrink Tubing Color Designations
0 - 5,000 ppm black shrink tubing on white wire
0 - 9,000 ppm black shrink tubing on green wire
0 - 5% vol. green shrink tubing on white wire
0 - 20% vol. black shrink tubing on red wire
0 - 50% vol. green shrink tubing on red wire
0 - 100% vol. red shrink tubing on green wire

8• Description 65-2396RK-XX-04 CO2Transmitter Operator’s Manual
Amplifier
The amplifier converts the electrical output from the detector to a 4 to 20 mA signal that
corresponds to the detection range and transmits the signal to a gas monitoring controller. A foam
gasket that orients the amplifier and keeps it from rotating is installed on the bottom of the
amplifier. The amplifier includes the controller terminal strip, detector terminal strip, span pot,
zero pot, and test points (see Figure 2).
Figure 2: Amplifier Component Location
Controller Terminal Strip
The controller terminal strip is a three position plug-in style terminal strip located near the top of
the amplifier. Use the controller terminal strip to wire the CO2transmitter to a controller.
Detector Terminal Strip
The detector terminal strip is a four position plug-in style terminal strip located below the
controller terminal strip. Use the detector terminal strip to connect the CO2transmitter to the
amplifier.
NOTE: The IR CO2detector is factory-wired to the detector terminal strip. See “Wiring the
Amplifier to a Controller” on page 13 for all wiring procedures related to the
transmitter.
Zero Pot
The zero pot is located in the upper left corner of the amplifier (see Figure 1). Use a small flat
blade screwdriver to turn the zero pot’s adjustment screw and adjust the amplifier’s target gas-free
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.
Factory Adjust Pot
G
LEL BWR S
PWR / SIG
Detector Terminal
Strip
Span Pot
Amplifier
Controller Terminal Strip
ZERO
Sensor
Current
mA SPAN
Zero Pot
Factory Adjust Pot
Jumper Pins,
Factory Use Only
- Test Point
+ Test Point

65-2396RK-XX-04 CO2Transmitter Operator’s Manual Description • 9
Span Pot
The span pot is located to the right of the zero pot (see Figure 1). Use a small flat blade
screwdriver to turn the span pot’s adjustment screw and adjust the amplifier’s gas response output
during the calibration procedure. Turn the adjustment screw clockwise to increase the gas
response and counterclockwise to decrease the gas response.
CAUTION: The amplifier includes two additional potentiometers. They are factory-set. Do not
adjust them.
Test Points
The test points are on the left side of the amplifier (see Figure 1). The test points produce a 100
mV to 500 mV output that corresponds to the transmitter’s 4 to 20 mA output. Use the test points
and a voltmeter to measure the amplifier’s output during the start-up and calibration procedures.
The black test point in the lower left corner is the negative (-) test point and the red test point
below the zero pot is the positive (+) test point.
Amplifier Junction Box
The amplifier junction box protects the amplifier and wiring connections made to the amplifier.
Use the top 3/4 NPT conduit hub to connect wiring from the amplifier to the controller. Use the
bottom 3/4 NPT conduit hub to wire the remotely installed CO2 detector. Use the cover on the
front of the junction box to access the interior of the junction box. The amplifier is factory
installed in the junction box. Three spacers installed on the back of the junction box controls the
distance of the junction box from a mounting surface.
Detector Junction Box
The detector junction box is intended to be installed remotely from the amplifier junction box.
The CO2detector is factory installed in the bottom 3/4 NPT conduit hub. A terminal strip is
provided for wiring connections and the detector is factory wired to one side of this terminal strip.
The other side of the terminal strip is for user-supplied wiring to the detector terminal strip located
in the amplifier junction box. This wiring should go through the top 3/4 NPT conduit hub. Three
spacers installed on the back of the junction box controls the distance of the junction box from a
mounting surface.

10 • Installation 65-2396RK-XX-04 CO2Transmitter Operator’s Manual
Installation
This section describes procedures to mount the CO2transmitter in the monitoring environment
and wire the transmitter to a controller.
Mounting the CO2Transmitter
1. Select a mounting site that is representative of the monitoring environment. Consider the
following when you select the mounting site:
• For the amplifier junction box, select a site where the junction box is not likely to be
bumped or disturbed. Make sure there is sufficient room to perform start-up, maintenance,
and calibration procedures. The site should be easily accessible.
• For the detector junction box, select a site where the target gas is likely to be found first.
For carbon dioxide, mount the remote detector at least six feet from the floor to minimize
the possibility of someone breathing on the unit. The exhaled CO2may cause an alarm.
• The junction boxes should be mounted no further than 200 feet from each other.
2. At the monitoring site you select, hang or mount the junction box with the detector facing
down (see Figure 2).
Figure 3: Mounting the CO2Transmitter
3.65
Rubber
Spacer,
3X
.38
5.25
9.00 MAX
J-Box
IR CO2
Detector
Calibration
Cup/Splash
Guard
2.70
.75
3/4 NPT
Female