RKI Instruments 65-2397-04 Series User manual

RKI Instruments, Inc.
www.rkiinstruments.com
65-2397-XX-04
CO2Transmitter
Operator’s Manual
Part Number: 71-0631
Revision: P1
Released: 4/7/23

2• 65-2397-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 6 and 12 months, but
can be required more often or less often based on your usage.

65-2397-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• 65-2397-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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mounting the CO2Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wiring the Detector to the Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wiring the Amplifier to a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

65-2397-XX-04 CO2Transmitter Operator’s Manual Overview • 5
Overview
This manual describes the 65-2397-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 65-2397-XX-04 CO2transmitter.
WARNING: When using the 65-2397-XX-04, you must follow the instructions and warnings
in this manual to assure proper and safe operation of the 65-2397-XX-04 and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 65-2397-XX-04 as described in this manual.
Table 1: Specifications
Target Gas Carbon Dioxide (CO2)
Sampling Method Diffusion
Signal Output 4 to 20 mA
Detection Range
65-2397-01-04: 0-9,000 ppm
65-2397-02-04: 0-5,000 ppm
65-2397-03-04: 0-5% Volume
65-2397-04-04: 0-20% Volume
65-2397-05-04: 0-50% Volume
65-2397-10-04: 0-100% Volume
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 65-2397-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 hydrogen detector, calibration cup/splash guard, 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
Black Detector J-Box
White
Green
B
Amplifier
Controller Terminal Strip
S
PWR / SIG
IR CO2 Detector
Calibration Cup/Splash Guard
WR
Amplifier J-Box
Detector Terminal
Strip
ZERO
SPAN
Red
G
LEL
Sensor
Current
mA

65-2397-XX-04 CO2Transmitter Operator’s Manual Description • 7
Infrared CO2Detector
The CO2detector consists of the detector housing body, detector housing cap, cap gasket, and the
plug-in sensor.
Figure 2: CO2Detector Component Location
Detector Housing Body
The detector housing body protects the electronic components within the housing. Use the
mounting threads at the top of the housing to screw the CO2detector into the 3/4 NPT hub on the
bottom of the junction box. 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.
The housing includes three sockets installed on a circuit board. These sockets accept the plug-in
sensor’s three pins to provide an electrical connection for the sensor. The circuit board with the
sockets conditions the sensor’s signal before the signal reaches the amplifier.
Housing Cap & Cap Gasket
The housing cap screws onto the detector housing. It retains the plug-in sensor and protects it
from damage. A foam gasket is installed inside the housing cap that seals against the sensor face.
A hydrophobic membrane on the outside of the cap face keeps water and particulates away from
the sensor face behind the cap. Unscrew the detector cap to access the plug-in sensor for
maintenance or replacement. A cap gasket seals the interface between the housing and cap.
Plug-In CO2Sensor
The plug-in sensor is secured in the detector assembly by the housing cap. The sensor produces a
millivolt output that corresponds to the detection range of the transmitter.
Hydrophobic
Membrane
Cap Gasket
Plug-In CO2 Sensor
Sensor Retainer
Detector Housing Cap
Detector Housing Body

8• Description 65-2397-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 3).
Figure 3: 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 12 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 3). 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

65-2397-XX-04 CO2Transmitter Operator’s Manual Installation • 9
Span Pot
The span pot is located to the right 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 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 3). 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.
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:

10 • Installation 65-2397-XX-04 CO2Transmitter Operator’s Manual
• 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 4: Mounting the CO2Transmitter
5.25 MAX
Rubber
Spacers,
3X
3.65
3/4 NPT
Female
IRCO2
Detector
J-Box
3.10
.75 .38
9.80 MAX
Calibration
Cup/Splash
Guard