65-2502RK/65-2510RK
Oxygen Detector
Operator’s Manual
Part Number: 71-0074RK
Revision: A
Released: 3/1/11
www.rkiinstruments.com
WARNING
Read and understand this instruction manual before operating
detector . Improper use of the dete ctor 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.
T ypical calibration frequencies for most applications a re between
3 and 6 months, but can be required more often or less often
based on your usage.
65-2502RK/65-2510RK Oxygen Detecto r
Product Warranty
RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free fro m 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 withi n tha t 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 ser v ice, 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 r esponsible for removal or r eplacement costs,
local repair costs, transportation costs, or contingent expenses incurred without our prior
approval.
a) Absorbent cartridges d) Batteries
b) Pump diaphragms and valves e) Filter elements
c) Fuses
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 fo r any accident or dama g e ca u s e d by the operation of
this gas monitor, and our warranty is limited to the replacement of parts or our complete
goods.
65-2502RK/65-2510R K Oxyg en Detector
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 Detecto r
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
65-2502RK/65-2510RK Oxygen De te c to r • 1
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 series of chemical and elect ronic reactions,
the detector produces a millivolt output that is proportional to the d e tection 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 install 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 detecto r to the juncti on 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.
Installation
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.
This section describes procedures to mount the oxygen detector in the monitoring
environment and wire the detector to a contro ller.
Mounting the Oxygen Detector
NOTE: If you are moun ting a 65-2510RK, it does not include a junction box and is
usually factory installed in one of a controller’s co nd uit 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. Ma ke sur e
there is sufficient room to perform start-up, maintenance, and calibration
procedures.
• Select a site that is at normal breathing level.
2 • 65-2502RK/65-2510RK Oxygen De tector
3/4 NPT
Female
2.70
0.38
.75
3.65
7.6 max
Spacer,
3X
J-Box
Oxygen
Detector
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 the controller is off before you make
wiring connections.
1. Turn off the contro ller.
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 w hite 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.
65-2502RK/65-2510RK Oxygen De te c to r • 3
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 op posite 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 disru pt the transmission of the detect or signal to the controller.
9. Connect the wires to the appropriate controller detector terminal strip. See the
controller operat o r’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. R KI controllers typically have a ground stud that is a convenient
grounding location.
4 • 65-2502RK/65-2510RK Oxygen De tector
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. Ve rify 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 ma nual.
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 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.
1. Screw the calibration cup onto the bottom of the ox ygen 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/o ff knob counterclockwise to open it. Gas will begin to flow.
5. Allow the gas to fl ow for two minutes.
6. Verify a reading 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/o ff 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 components of the calibration kit in a safe and conv enient place.
65-2502RK/65-2510RK Oxygen De te c to r • 5
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
test procedure.
NOTE: Performing a response test on the oxygen d etector may cause alarms. Be sure to
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 int o the bottom of the oxygen detector housi ng.
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.
6 • 65-2502RK/65-2510RK Oxygen De tector
Troubleshooting
The troubleshooting guide describes symptoms, probable causes, and recommended
action for problems you may encounter with the oxygen detector.
NOTE: This tro ubleshooting 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 mont hs.
Some applications may
require a more freque nt
calibration schedule.
Replacing the Oxygen Detector
• The detector w iring 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 det ect or.
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 contro ller.
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 cove r.
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
65-2502RK/65-2510RK Oxygen De te c to r • 7
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 cove r.
9. Turn 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 co ntinue 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 a re minima l 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 th e te st 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.
Prepari ng for Ca libration
NOTE: Calibrating the oxygen detector may cause alarms. Be sure to put the controller
into its calibration program or disable external alarms before calibrating.
8 • 65-2502RK/65-2510RK Oxygen De tector
1. Screw the calibration cup onto the detector housing.
2. Screw the regulator into the zero air calibration cylind er. 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 cali bration program. See the controller operator’s manual
for instructions to enter the calibration program.
Setting the Fresh Air Reading
1. Follow the directions in the controller’s instruction manual for setting the fresh air
reading to 20.9% oxygen.
2. When the instructio ns 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/o ff 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/o ff 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.
65-2502RK/65-2510RK Oxygen De te c to r • 9
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 that the controller display reading increases and stabilizes at 20.9% oxygen.
3. Store the components of the calibration kit in a safe and convenient p lace.
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 including junction box.
65-2510RK Oxygen detector, conduit-mounting, not including junction b ox
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-01 Calibration cylinder (100% nitroge n, 34-liter)
81-1050RK Regulator with gauge and knob, 0.5 LPM, for 17 liter and 34 liter
steel calibration cylinders
81-1117RK Calibration cup
10 • 65-2502RK/65-2510RK Oxygen D etector
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