RKI Instruments 65-2502RK User manual

65-2502RK/65-2510RK

Oxygen Detector

Operator’s Manual

Part Number: 71-0074RK

Revision: A

Released: 3/1/11

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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.

65-2502RK/65-2510RK Oxygen Detector

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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 fr o m 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:

W arranty 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 , a nd we are not responsible for r emoval 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.

a) Absorbent cartridges d) Batteries
b) Pump diaphragms and valves e) Filter elements
c) Fuses

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 inde mn ification fo r a ny accident or damage caus ed b y t he op e ration of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.

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Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mounting the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Wiring the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Replacing the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

65-2502RK/65-2510RK Oxygen Detector

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Overview

This manual describes the 65-2502RK oxygen 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 oxygen detector.

The 65-2502RK oxygen detector includes a junction box. This manual may also be used for
the 65-2510RK oxygen detector which does not include a junction box and is normally
mounted in one of a controller’s conduit hubs. If you are using a 65-2510RK oxygen
detector, disregard all references to the junction box and junction box terminal strip.

Specifications

Table 1 lists specifications for the oxygen detector.

Table 1: 65-2502RK/65-2510RK Specifications

Target Gas Oxygen
Sampling Method Diffusion
Detection Range 0 - 25.0% O

Accuracy ± 0.5% O
Response Time 90% in 30 seconds

Output Millivolt (mV)

WARNING: When using the 65-2502RK/65-2510RK, you must follow the instructions

and warnings in this manual to assure proper and safe operation of the
65-2502RK/65-2510RK and to minimize the risk of personal injury. Be sure
to maintain and periodically calibrate the 65-2502RK/65-2510RK as
described in this manual.

2

2

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Description

This section describes the components of the oxygen detector. The detector includes the
oxygen cell, detector housing, and detector connector. This section also describes the
junction box.

Oxygen Detector

The sensing components of the detector are encapsulated within a conduit mounting
black anodized alumi n um ho u sin g. Through a ser ies o f ch emi cal an d el ect ronic reactio ns ,
the detector produces a millivolt output that is proportional to the detection range. 3 /4”
NPT mounting threads at the top of the detector allow you to mount the detector to the
junction box or a 3/4” NPT conduit fitting. Two color-coded leads extend from the top of
the detector. The leads allow you to connect the detector to a controller.

Junction Box

The junction box allows you to insta ll the oxygen detector at a mounting site that is
remote from a controller, and it protects the detector wiring connections. Two conduit
hubs allow you to mount the oxygen detector to the junction box and connect the wiring
from the detector to a 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 process. 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 oxygen detector in the monitoring
environment and wire the detector to a controller.

Mounting the Oxygen Detector

NOTE: If you are mounting a 65-2510RK, 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.

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 sur e

there is sufficient room to perform start-up, maintenance, and calibration
procedures.

• Select a site that is at normal breathing level.

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3/4 NPT

Femal e

2.70

0.38

.75

3.65

7.6 max

Space r,
3X

J-Box

Ox y g e n

Detec tor

Figure 1: Mounting the Oxygen Detector

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

facing down (see Figure 1).

Wiring the Oxygen Detector to a Controller

WARNING: Always verify that the power to t he controller is off before you make

wiring connections.

1. Turn off the controller.

2. Turn off or unplug incoming 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 white and green wires are connected to the appropriate controller
detector terminals and skip to “Start Up” on page 5. See Figure 2, the controller
operator’s manual, and the controller’s detector head specification sheet for the
65-2510RK detector for the wiring connections.

4. Remove the junction box cover.

5. Guide a two-conductor, shielded cable or two 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.

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6. Connect the wires to the terminals using the terminal block.

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

detector. You will connect the oppo site 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 po wer

cable may disrupt the transmission of the detector signal to the controller.

9. Connect the wires to the appropriate controller detector terminal strip. See the
controller operator’s manual and the controller’s detector head specification sheet for
the 65-2502RK detector.

Green (-)

White (+)

Controller Oxygen
Detector Terminals

J-box

Terminal Strip

White

Detector Wires

Green

Oxygen Detector

Figure 2: Wiring the Oxygen Detector 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.

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Start Up

This section describes procedures to start up the oxygen detector 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 instruction manual.

3. Turn on or plug in the incoming 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 manu al.

CAUTION: Allow the detector to warm up for 5 minutes before you continue with the next

section, “Setting the Fresh Air Reading”.

Setting the Fresh Air Reading

NOTE: If you can verify that the detector is in a fresh air environment (environment

known to be of normal oxygen content and free of toxic and combustible gases),
it is not necessary to apply zero air when verifying or setting the fresh air
reading.

The procedure below describes applying zero emission air, usually called zero air, using a
calibration kit that includes a calibra tion cup, calibration gas, sample tubing, and a fixed
flow regulator with an on/off knob. RKI Instruments, Inc. recommends using a 0.5 LPM
(liters per minute) fixed flow regulator.

1. Screw the calibration cup onto the bottom of the oxygen detector.

2. Screw the regulator into the zero air 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 two minutes.

6. Verify a readin g of 20.9% oxygen at the controller.
If the display reading is 20.9% oxygen, the oxygen detector is in normal operation and

start up is complete. Proceed to step 7 to disassemble the calibration kit.
If the display reading is not 20.9% oxygen, set the fresh air reading according to the

controller’s operator’s manual.

7. Turn the regulator’s on/off knob clockwise to close it.

8. Unscrew the regulator from the zero air calibration cylinder. For convenience, leave
the sample tubing connected to the regulator and the calibration cup.

9. Unscrew the regulator from the cylinder and remove the calibration cup from the
detector.

10. Store the comp onents of the calibrat ion kit in a safe and convenient place.

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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 oxygen detector. It includes daily, monthly, and quarterly procedures.

Daily

Verify a display reading of 20.9% oxygen at the controller. Investigate significant changes
in the reading.

Monthly

This procedure describes a test to verify that the oxygen detector responds properly to
oxygen deficiency.

WARNING: The controller is not an active gas monitoring device during the response

NOTE: Performing a respon se test on the oxygen detector may cause alarms. Be sure to

test procedure.

put the controller into its calibration program or disable external alarms before
performing this test.

1. Place the controller into its calibration program or disable external alarms.

2. Verify that the controller display reading is 20.9% oxygen.
If the controller reading is not 20.9% oxygen, set the fresh air reading, then continue

this procedure. See the controller instruction manual for directions to set the fresh air
reading.

3. Exhale into the bottom of the oxygen detector housing.

4. Stop exhaling into the bottom of the detector, then verify that the reading on the
controller display decreased from the normal reading of 20.9% oxygen.

NOTE: If the reading does not decrease, calibrate the detector as described in the

Calibration section of this manual.

5. When the display reading rises above the decreasing alarm setpoint, return the
controller to normal operation.

Quarterly

Calibrate the detector as described in the Calibration section of this manual.

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Troubleshooting

The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the oxygen detector.

NOTE: This troubleshooting guide describes detector problems only. See the controller

instruction manual for problems you may encounter with the controller.

Table 2:Troubleshooting the Oxygen Detector

Condition Symptom(s) Probable Causes Recommended Action

Fail Condition • Controller indicates a

Slow or No
Response/
Difficult or
Unable to
Calibrate

fail condition.

• Detector responds
slowly or does not
respond to response
test.

• Unable to accurately
set the fresh air or
zero reading during
calibration.

• Detector requires
frequent calibration.

Note: Under “normal”
circumstances, the
detector requires
calibration once every
three months.

Some applications may
require a more frequent
calibration schedule.

Replacing the Oxygen Detector

• The detector wiring is
disconnected or
misconnected.

• The detector is
malfunctioning.

• The calibration cylinder
is low, out-dated, or
defective.

• 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.

1. Verify that the calibration cylinder
contains an adequate supply of a
fresh test sample.

2. If the calibration/response difficulties
continue, replace the detector.

3. If the calibration/response difficulties
continue, contact RKI for further
instruction.

1. Turn off the controller.

2. Turn off power to the cont roller.

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

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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 2 for wiring to a generic
controller. See the controller operator’s manual and the controller’s detector head
specification sheet for the 65-2510RK 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 2). See the controller operator’s manual and the controller’s detector head
specification sheet for the 65-2502RK 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.

9. Tu rn on power to the controller.

10. Turn on the controller and place into normal operation.

CAUTION: Allow the replacement detector to warm up for 5 minutes before you continue with

the next step.

11. Calibrate the replacement detector as described in the Calibration section of this
manual.

Calibration Frequency

Although there is no particular calibration frequency that is correct for all applications, a
calibration frequency of every 3 months is adequate for most oxygen detector
applications. Unless experience in a particular application dictates otherwise, RKI
Instruments, Inc. recommends a calibration frequency of every 3 months for the oxygen
detector.

If an application is not very demanding, for example detection in a clean, temperature
controlled environment, and calibration adjustments are minimal at calibration, then a
calibration frequency of every 6 months is adequate.

If the application is very demanding, for example if the environment is not well
controlled, then more frequent calibration than every 3 months may be necessary.

Calibration

This section describes how to calibrate the oxygen detector. It includes procedures to
assemble the calibration kit, set the fresh air reading, set the zero reading and return to
normal operation. It describes the test using a calibration kit that includes a calibration
cup, calibration gas, sample tubing, and a fixed flow regulator with an on/off knob. RKI
Instruments, Inc. recommends using a 0.5 LPM (liters per minute) fixed flow regulator.

Preparing for Calibration

NOTE: Calibrating the oxygen detector may cause alarms. Be sure to put the controller

into its calibration program or disable external al arms before calibrating.

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1. Screw the calibration cup onto the detector housing.

2. Screw the regulator into the zero air calibration cylinder. Make sure the regulator is
off. It is off when the on/off knob is turned all the way clockwise.

3. Use the sample tubing to connect the regulator to the calibration cup.

NOTE: If you can verify that the oxygen detector is in a fresh air environment, you do

not need to apply zero air to the detector before adjusting the fresh air reading.

4. Put the controller into its calibration program. See the controller operato r’s manual
for instructions to enter the calibration program.

Setting the Fresh Air Reading

1. Follow the directions in the controller’s instruction manua l for setting the fresh air
reading to 20.9% oxygen.

2. When the instructions call for exposing the detector to zero air, turn the regulator’s
on/off knob counterclockwise to open it.

3. Allow the gas to flow to the detector for 2 minutes.

4. Set the fresh air reading according to the controller operator’s manual.

5. Turn the regulator’s on/off knob clockwise to close it.

6. Unscrew the regulator from the zero air calibration cylinder. Leave the sample tubing
connected to the regulator and the calibration cup.

NOTE: Depending on the size of your zero air cylinder , it is possible that you will have a

different regulator for the zero air cylinder and the nitrogen gas cylinder. If
necessary to fit the nitrogen gas cylinder, change the regulator.

Setting the Zero Reading

1. Screw the regulator into the 100% nitrogen calibration cylinder.

2. Follow the instructions in the controller’s operator’s manual for setting the oxygen
zero reading.

3. When the instructions call for exposing the detector to gas, turn the regulator’s on/off
knob counterclockwise to open it.

4. Allow the gas to flow to the detector for 2 minutes.

5. Set the zero reading according to the controller operator’s manual.

6. Turn the regulator’s on/off knob clockwise to close it.

7. Unscrew the regulator from the calibration cylinder.

8. Unscrew the calibration cup from the detector.

NOTE: For convenience, leave the components of the calibration kit connected by the

sample tubing.

Returning to Normal Operation

1. When the display reading rises above the decreasing alarm setpoint, return the
controller to normal operation.

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Parts List

NOTE: If you do not allow the oxygen reading to increase above the decreasing alarm

point, then unwanted alarms may occur.

2. Verify tha t the controller display reading increases and stabilizes at 20.9% oxygen.

3. Store the comp onents of the calibration kit in a safe and convenient place.

Table 3 lists replacement parts and accessories for the oxygen detector.

Table 3: Parts List

Part Number Description

06-1248RK Sample tubing (3/16 in. x 5/16 in.; specify length when ordering)
18-04000RK-01 Junction box with spacers
65-2502RK Oxygen detector in cluding junction box.
65-2510RK Oxygen detector, conduit-mounting, not including junction box
71-0074RK 65-2502RK/65-2510RK Oxygen Detector Operator’s Manual (this

document)
81-F301RK-LV Calibration kit (34 liter)
81-0076RK-01 Zero air calibration cylinder (34 liter)
81-0078RK Calibration cylinder (100% nitrogen, 17-liter)
81-0078RK-0 1 C alibration cylinder (100% nitrogen, 34-liter)
81-1050RK Regulat or with gauge and knob, 0.5 LPM, for 17 liter and 34 liter

steel calibration cylinders
81-1117RK Calibration cup

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