RKI 61-1007RK User manual

www.rkiinstruments.com
61-1007RK/61-0198RK
CO2Detector
Operator’s Manual
Part Number: 71-0200RK
Revision: A
Released: 4/12/11

61-1007RK/61-0198RK Combustible Gas Detector
WARNING
Read and understand this instruction manual before operating
detector. 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
6 and 12 months, but can be required more often or less often
based on your usage.

61-1007RK/61-0198RK 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

61-1007RK/61-0198RK Combustible Gas Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IR CO2Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting the CO2Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wiring the CO2Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Setting the Zero Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Replacing the CO2Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting the Response Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

61-1007RK/61-0198RK Combustible Gas Detector • 1
Overview
This manual describes the 61-1007RK 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 61-1007RK CO2detector includes a junction box. This manual may also be used for
the 61-0198RK 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 61-0198RK CO2detector, disregard all references to the junction box and
junction box terminal block.
Specifications
Table 1 lists specifications for the CO2detector.
WARNING: When using the 61-1007RK, you must follow the instructions and warnings
in this manual to assure proper and safe operation of the 61-1007RK and to
minimize the risk of personal injury. Be sure to maintain and periodically
calibrate the 61-1007RK as described in this manual.
Table 1: 61-1007RK Specifications
Detection Range With Junction Box
61-1007RK-02: 0 - 5,000 ppm CO2
61-1007RK-03: 0 - 5% Volume CO2
61-1007RK-05: 0 - 50% Volume CO2
61-1007RK-10: 0 - 100% Volume CO2
Without Junction Box
61-0198RK-02: 0 - 5,000 ppm CO2
61-0198RK-03: 0 - 5% Volume CO2
61-0198RK-05: 0 - 50% Volume CO2
61-0198RK-10: 0 - 100% Volume CO2
Area Classification Explosionproof for Class I, Groups B, C, and D
Sampling Method Diffusion
Response Time 90% in 45 seconds
Accuracy ± 5% of reading or ± 2% of full scale (whichever is greater)

2 • 61-1007RK/61-0198RK Combustible Gas Detector
Description
The 61-1007RK CO2detector has four versions, the 61-1007RK-02 which has a detection
range of 0 - 5,000 ppm, the 61-1007RK-03 which has a detection range of 0 - 5% volume,
the 61-1007RK-05 which has a detection range of 0 - 50% volume, and the 61-1007RK-10
which has a detection range of 0 - 100% volume. The detector is an infrared type of
detector. This section describes the components of the 61-1007RK and 61-0198RK
detectors. The 61-1007RK includes the 61-0198RK detector and a junction box. A four
point terminal strip is provided inside the junction box for detector connections. The
61-0198RK does not include a junction box.
Figure 1: 61-1007RK Component Location
J-Box
White
Green Rubber
Spacer
s,
3X
IR CO2 Detector
Black
Red

61-1007RK/61-0198RK Combustible Gas Detector • 3
61-0198RK Infrared CO2Detector
The 61-0198RK 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 controller.
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
controller.
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 detector.
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 Housing Cap
Plug-In IR CO2 Sensor
Cap Gasket
Hydrophobic
Membrane
Detector Housing Body

4 • 61-1007RK/61-0198RK Combustible Gas Detector
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 ensure that there is enough room to install a
calibration cup on the detector during calibration.
Installation
This section describes procedures to mount the CO2detector in the monitoring
environment and wire it to a controller. If you purchased a 61-0198RK 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 3: Mounting the CO2Detector
3.10
.75 .38
Rubber
Spacers
3X
3.65
3/4 NPT
Female
1 1/2-20 Thread for Calibration Cup
J-Box
IR CO2 Sensor
6.80 Max

61-1007RK/61-0198RK Combustible Gas Detector • 5
2. At the mounting site you select, hang or mount the junction box with the detector
facing down (see Figure 3).
Wiring the CO2Detector to a Controller
WARNING: Always verify that the power to the controller is off before you make
wiring connections.
1. Turn off the controller.
2. Turn off or unplug power to the controller.
3. If the detector is mounted remotely from a controller using the junction box, proceed
to step 4.
If the detector is mounted directly to a controller, it is normally factory wired. Confirm
that the detector’s wires are connected to the appropriate controller detector terminals
and skip to “Start Up” on page 7. See Figure 4, the controller operator’s manual, and
the controller’s detector head specification sheet for the 61-0198RK detector for the
wiring connections.
4. Remove the cover from the junction box.
5. Guide a four-conductor, shielded cable or four wires in conduit through the top
conduit hub of the junction box. Use appropriate conduit fittings and construction
technique for the environmental rating of the junction box. The junction box is rated
NEMA 4X.
6. Connect the wires to the terminals opposite the detector leads.
CAUTION: Leave the shield drain wire insulated and disconnected at the 61-1007RK. You will
connect the opposite end of the cable’s drain wire at the controller.
7. Secure the junction box cover to the junction box.
8. Route the cable or wires in conduit leading from the detector through one of the
conduit hubs at the controller. 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 conduit hub. The power
cable may disrupt the transmission of the detector signal to the controller.
9. Connect the wires to the applicable controller terminal strip. See the controller
operator’s manual and the controller’s detector head specification sheet for the
61-1007RK detector.

6 • 61-1007RK/61-0198RK Combustible Gas Detector
Figure 4: Wiring the CO2Detector to a Controller
10. 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.
Controller LEL
Detector Terminals
GREEN
WHITE
RED
BLACK
White
Cable shield
IR CO2 Detector
Green
Black
J-Box
Red

61-1007RK/61-0198RK Combustible Gas Detector • 7
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, “Setting the Zero Signal”.
Setting the Zero Signal
Since there is a background of CO2in air of typically 200 - 400 ppm, it is necessary to use a
calibration kit with a CO2free gas to set the zero signal of a low range CO2detector. Fresh
air can be used to zero the detector if a 0-50 %volume or 0-100 %volume detector is being
used.
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.

8 • 61-1007RK/61-0198RK Combustible Gas 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 CO2detector. It includes daily, monthly, and biannual procedures.
Daily
Verify a display reading at the controller of the background concentration of CO2. Typical
background concentrations of CO2vary from about 200 to 400 ppm depending on
location. The 0-5,000 ppm and 0-5 %volume detectors will display a reading in a fresh air
environment because they have low ranges. The 0-50 %volume and 0-100% volume
detectors will not display a reading in fresh air because their ranges are too large.
Investigate significant changes in the display 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 for the channel you are testing is consistent
with typical background levels of CO2.
If the reading is not consistent with typical background levels of CO2, 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.

61-1007RK/61-0198RK Combustible Gas Detector • 9
NOTE: If the reading is not within ± 20% of the gas concentration, calibrate the detector
as described in “Calibration” on page 12.
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.
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 12.
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.
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 plug-in sensor is
not properly plugged
into the three-socket
pattern in the detector
housing body.
• 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. Confirm that the plug-in sensor is
installed properly.
3. Calibrate the detector.
4. If the fail condition continues, replace
the detector.
5. If the fail condition continues, contact
RKI for further instruction.

10 • 61-1007RK/61-0198RK Combustible Gas Detector
Replacing Components of the CO2Detector
This section includes a procedure to replace the hydrophobic membrane, a procedure to
replace the plug-in IR CO2sensor, and a procedure to replace the entire CO2detector
assembly. In most cases, it is not necessary to replace the entire detector assembly.
Replacing the Hydrophobic Membrane
1. Turn off the controller.
2. Turn off or unplug incoming power to the controller.
3. Unscrew the detector housing cap from the detector housing body.
4. Gently pry up the edge of the white hydrophobic membrane with a small flat blade
screwdriver or a similar tool.
5. Peel off the hydrophobic membrane. It may be necessary to clean off the detector
housing cap face to remove any residue left from the adhesive backed membrane.
6. Install the new membrane in the recess on the face of the detector housing cap.
7. Make sure the cap gasket is in place and screw the detector housing cap back onto the
detector housing body.
8. Turn on the power to the controller.
9. Turn on the controller and place it into normal operation.
Replacing the Plug-In CO2Sensor
CAUTION: The plug-in 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 contact 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
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.
• Thecalibration cylinder
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.
Table 2:Troubleshooting the CO2Detector (Continued)
Condition Symptom(s) Probable Causes Recommended Action

61-1007RK/61-0198RK Combustible Gas Detector • 11
lose the cap gasket.
4. Unplug and remove the plug-in IR CO2sensor.
5. Carefully plug the replacement sensor into the socket pattern that is located in the
detector housing.
6. Make sure the cap gasket is in place and screw the detector housing cap back onto the
detector housing body.
7. Turn on power to the controller.
8. Turn on the controller and place it into normal operation.
CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue with the
next step.
9. Calibrate the detector as described in “Calibration” on page 12.
Replacing the CO2Detector
NOTE: In most cases it is only necessary to replace the IR CO2plug-in sensor.
1. Turn off the controller.
2. Turn off power to the controller.
3. If the detector is installed directly on a controller, open the controller door.
If the detector is installed remotely from a controller in a junction box, remove the
junction box cover.
4. If the detector is installed directly on a controller, disconnect the detector leads from
the detector terminal strip in the controller. Note the position of the color-coded leads
as you remove them.
If the detector is installed remotely from a controller in a junction box, 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 controller conduit hub or junction box conduit hub.
6. Guide the detector leads of the replacement detector through the controller conduit
hub or junction box conduit hub, then screw the mounting threads of the detector into
the hub. If necessary for environmental conditions, apply thread sealant or teflon tape
to the hub and/or detector threads to seal them.
7. If the detector is installed directly on a controller, connect the detector leads to the
appropriate detector terminal strip terminals. See Figure 4 on page 6 for wiring to a
generic controller. See the controller operator’s manual and the controller’s detector
head specification sheet for the 61-0198RK detector for wiring specific to your
controller.
If the detector is installed remotely from a controller in a junction box, connect the
detector leads to the terminal block the same way the old detector was wired (see
Figure 4 on page 6). See the controller operator’s manual and the controller’s detector
head specification sheet for the 61-1007RK detector to verify the connections to the
controller are correct.
8. If the detector is installed remotely from a controller in a junction box, reinstall the
junction box cover.

12 • 61-1007RK/61-0198RK Combustible Gas Detector
9. Turn on or plug in power to the controller.
10. Turn on the controller.
11. Calibrate the replacement detector as described in“Calibration” on page 12.
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 prepare
for calibration, 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 reading, 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.
Preparing For Calibration
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.
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
Since there is a background of CO2in air of typically 200 - 400 ppm, it is necessary to use a
calibration kit with a CO2free gas to set the zero signal of a low range CO2detector. Fresh
air can be used to zero the detector if a 0-50 %volume or 0-100 %volume detector is being
used.

61-1007RK/61-0198RK Combustible Gas Detector • 13
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.
3. Turn the regulator’s on/off knob clockwise to close the regulator.
4. Set the zero reading according to the controller’s operator’s manual.
5. 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.
3. Turn the regulator’s on/off knob clockwise to close the regulator.
4. Set the response reading according to the controller’s operator’s manual.
5. Unscrew the CO2cylinder from the regulator.
Returning to Normal Operation
1. Remove the sample tubing from the regulator.
2. Remove the calibration cup from the detector. Leave the sample tubing connected to
the calibration cup for convenience.
3. 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 to decrease below the alarm points, then
unwanted alarms may occur.
4. Verify that the controller display reading decreases and stabilizes at a typical
background CO2level. The 0-5,000 ppm and 0-5 %volume detectors will display a
reading in a fresh air environment because they have low ranges. The 0-50 %volume
and 0-100 %volume detectors will not display a reading in fresh air because their
ranges are too large.
5. Store the components of the calibration kit in a safe and convenient place.

14 • 61-1007RK/61-0198RK Combustible Gas Detector
Parts List
Table 3 lists replacement parts and accessories for the 61-1007RK and 61-0198RK CO2
detectors.
Table 3: Parts List
Part Number Description
07-0039RK Detector housing cap gasket
18-0400RK-01 Junction box with spacers
33-0157RK Hydrophobic disk membrane for detector cap
61-0198RK-02 Infrared CO2detector, 0 - 5,000 ppm
61-0198RK-03 Infrared CO2detector, 0 - 5% Volume
61-0198RK-05 Infrared CO2detector, 0 - 50% Volume
61-0198RK-10 Infrared CO2detector, 0 - 100% Volume
61-5040RK-02 CO2replacement plug-in sensor, 0 - 5,000 ppm
61-5040RK-03 CO2replacement plug-in sensor, 0 - 5% Volume
61-5040RK-05 CO2replacement plug-in sensor, 0 - 50% Volume
61-5040RK-10 CO2replacement plug-in sensor, 0 - 100% Volume
71-0200RK 61-1007RK/61-0198RK CO2Detector Operator’s Manual (this
document)
81-0070RK-01 Steel calibration cylinder, 2,000 ppm CO2in nitrogen, 34 liter
81-0072RK-01 Steel calibration cylinder, 2.5% CO2in nitrogen, 34 liter
81-0073RK-01 Steel calibration cylinder, 15% CO2in 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
81-1117RK 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