RKI Instruments CT-7 Series User manual

www.rkiinstruments.com

65-2302/65-2303

CT-7 Series

Toxic Detector

Operator’s Manual

Part Number: 71-0422

Revision: H

Released: 6/24/21

2 • 65-2302/65-2303 Toxic 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 3 and 6 months, but can

be required more often or less often based on your usage.

65-2302/65-2303 Toxic Detector • 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:

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

4 • 65-2302/65-2303 Toxic Detector

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

65-2302 Toxic Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Mounting the Toxic Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wiring the Toxic Detector to a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Setting the Zero (Fresh Air) Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replacing Components of the Toxic Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Special Note About Calibrating a ClO2Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Setting the Zero (Fresh Air) Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Setting the Response Reading (Span) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

65-2302/65-2303 Toxic Detector • 5

Overview

This manual describes the 65-2302 and 65-2303 toxic detectors. This manual also describes

how to install, start up, maintain, and calibrate the toxic detector when used with a gas

monitoring controller. A parts list at the end of this manual lists replacement parts and

accessories for the toxic detector.

The 65-2303 toxic detector includes the 65-2302 toxic detector and a junction box.

The 65-2302 toxic detector does not include a junction box and is normally mounted in one of

a controller’s conduit hubs. If you are using a 65-2302 toxic detector, disregard all references

to the junction box and junction box terminal strip.

The 65-2302 and 65-2303 detectors can be used for various target gases which are listed in

Table 1 below.

Specifications

WARNING: Do not use this product in a manner not specified in this instruction manual.

Table 1: Specifications

Target Gas and

Detection Range

Ammonia (NH3) 0 - 75 ppm • 65-2302-NH3-75

• 65-2303-NH3-75

Ammonia (NH3) 0 - 100 ppm • 65-2302-NH3-1

• 65-2303-NH3-1

Ammonia (NH3) 0 - 200 ppm • 65-2302-NH3-2

• 65-2303-NH3-2

Ammonia (NH3) 0 - 500 ppm • 65-2302-NH3-5

• 65-2303-NH3-5

Chlorine (Cl2) 0 - 3.00 ppm • 65-2302-CL2-3

• 65-2303-CL2-3

Chlorine (Cl2) 0 - 5.00 ppm • 65-2302-CL2-5

• 65-2303-CL2-5

Chlorine (Cl2) 0 - 10.0 ppm • 65-2302-CL2-10

• 65-2303-CL2-10

Chlorine Dioxide (ClO2) 0 - 1.00 ppm • 65-2302-CLO2-1

• 65-2303-CLO2-1

Chlorine Dioxide (ClO2) 0 - 3.00 ppm • 65-2302-CLO2-3

• 65-2303-CLO2-3

Chlorine Dioxide (ClO2) 0 - 5.00 ppm • 65-2302-CLO2-5

• 65-2303-CLO2-5

Hydrogen Cyanide (HCN) 0 - 15 ppm • 65-2302-HCN-15

• 65-2303-HCN-15

6 • 65-2302/65-2303 Toxic Detector

WARNING: When using the 65-2302/65-2303, you must follow the instructions and

warnings in this manual to assure proper and safe operation of the 65-2302/

65-2303 and to minimize the risk of personal injury. Be sure to maintain and

periodically calibrate the 65-2302/65-2303 as described in this manual.

Description

This section describes the components of the 65-2302 and 65-2303. The 65-2303 includes the

65-2302 toxic detector and a junction box. The 65-2302 does not include a junction box.

Figure 1 below shows the components of the 65-2303.

Sampling Method Diffusion

Accuracy ± 10% of reading or ± 5% of full scale (whichever is greater)

Response Time T90 in 60 seconds

Operating Temperature &

Humidity

-4°F to 104°F (-20°C to 40°C)

Table 1: Specifications

3/4 NPT Conduit Hub

Junction Box

Detector

Figure 1: 65-2303 Component Location

65-2302/65-2303 Toxic Detector • 7

65-2302 Toxic Detector

The 65-2302 toxic detector consists of the detector housing body, detector housing cap, cap

gasket, and the plug-in sensor.

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 detector into a 3/4 NPT hub. Two

wires extend from the top of the detector housing body. Use these wires to connect the

detector to a controller. One of the wires is black and one of the wires is color-coded

depending on the detector type. See Figure 4 on page 10 for the color code assignments.

The housing body includes a four-socket pattern at the bottom of the housing body. The plug-

in sensor mates to this socket pattern. A pre-amplifier located between the sockets and the two

wires conditions the sensor’s signal before the signal reaches the controller. Each plug-in

sensor type (Cl2for example) requires a different pre-amplifier, so there is a different detector

housing body for each gas type.

Housing Cap and Cap Gasket

The housing cap screws onto the detector housing. It retains the sensor and protects it from

damage. A foam gasket inside the housing cap seals against the face of the sensor when the

cap is screwed on the housing body. Unscrew the detector cap to access the sensor for

replacement. A cap gasket seals the interface between the housing and cap.

Plug-in Sensor

The plug-in sensor is secured in the detector assembly by the housing cap. There is a different

sensor for each target gas. Through a series of chemical and electrical reactions, the sensor

produces an electrical output that corresponds to the detection range of the sensor. A

VersaporR membrane is installed on the sensor face for protection from water and debris.

Junction Box

The junction box protects the detector wiring connections and allows you to install the toxic

detector at a mounting site that is remote from a controller. Two conduit hubs allow you to

mount the toxic detector to the junction box and connect the wiring from the detector to a

Plug-in Sensor

(different for each detector type)

Detector

Housing Cap

VersaporR Membrane

Detector Housing Body

(different for each detector type)

Cap Gasket

Figure 2: 65-2302 Toxic Detector Component Location

8 • 65-2302/65-2303 Toxic Detector

controller. 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. A terminal block within the junction box

facilitates the wiring connections. A cover on the front of the junction box allows access to the

interior of the junction box.

Installation

This section describes procedures to mount the toxic detector in the monitoring environment

and wire the detector to a controller.

Mounting the Toxic Detector

NOTE: If you are installing a 65-2302, it does not include a junction box and is usually

factory installed in one of a controller’s conduit hubs or may be field installed using

the 3/4 NPT threads on the end with the wires. The 65-2303 includes a junction box

as shown in Figure 3 below.

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.

65-2302/65-2303 Toxic Detector • 9

NOTE: If your application does not require a specific mounting site, mount the detector at

approximately breathing level.

2. At the mounting site you select, hang or mount the junction box with the detector facing

down (see Figure 3).

CAUTION:Mount the toxic detector with the detector facing down (see Figure 3.)

Wiring the Toxic Detector to a Controller

WARNING: Always verify that 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, connect the detector’s color-coded and

black wires to the appropriate controller detector terminals (see Figure 4 for the color

coding of the non-black wire) and skip to the Startup Section.

4. Remove the junction box cover.

Figure 3: Outline and Mounting Dimensions

Rubber

Spacer, 3X

.38

.75

3.10

Detector

+3/4" NPT

7.30 .25

3.65

65-2302

1 1/2-20 Thread for

Calibration Cup

Ø1.75

3/4 NPT

Conduit Hub

1 1/2-20 Thread for

Calibration Cup

Junction

Box

65-2303

6.70 Max

.75

1.22

10 • 65-2302/65-2303 Toxic Detector

5. Guide a two-conductor, shielded cable or two wires in conduit through the unused 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 two wires to the detector using the terminal block.

CAUTION:If using shielded cable, leave the drain wire insulated and disconnected at the

detector. 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 leading from the toxic detector through one of the conduit hubs at

the controller housing. 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 65-2302 or 65-2303

detector.

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.

(+) See Table

CL2

CLO2

HCN violet

yellow

Controller Detector Terminals,

Typical Designations

Controller Housing

Terminal Strip

Detector

Black (S)

Shielded

Cable

Gas Type + Wire

white

redNH3

Figure 4: Wiring to a Controller

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