RKI Instruments 65-2511RK, 65-2512RK Operating Manual

65-2511RK/65-2512RK

Oxygen Detector

Operator’s Manual

Part Number: 71-0109RK
Revision A
Released: 12/14/05

www.rkiinstruments.com

Product W arranty

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:

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

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.

65-2511RK/65-2512RK Oxygen Detector• 2

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mounting the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Wiring the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Replacing the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

65-2502RK/65-2510RK Oxygen Detector• 3

Overview

This manual describes the 65-2512RK 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 65-2512RK oxygen detector includes a junction box. This manual may also be used for
the 65-2511RK 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 65-2511RK 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: 65-2511RK/65-2512RK Specifications

Target Gas Oxygen
Sampling Method Diffusion
Detection Range 0 - 25.0% oxygen
Response Time 90% in 30 seconds
Operating Temperature -20° C to 45° C
Output Millivolt (mV)

65-2511RK/65-2512RK Oxygen Detector• 4

Description

This section describes the oxygen detector and the junction box.

Oxygen Detector

The detector’s sensing element along with signal conditioning components are
encapsulated within a conduit mounting black anodized aluminum housing. The sensing
element used is a capillary type that is not susceptible to output changes with changes in
atmospheric pressure.Through a series of chemical and electronic reactions, 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 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 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 insure 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 controller.

Mounting the Oxygen Detector

NOTE: If you are mounting a 65-2511RK, 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 65-2512RK
includes a junction box as shown in Figure 1 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 that is at normal breathing level.

65-2502RK/65-2510RK Oxygen Detector• 5

3.6

Threads For
Calibration Cup
Installation

2.7
.75

.38

6.7 MAX

Spacer,
3X

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 controller.

2. Turn off or unplug incoming power.

3. Remove the cover from the junction box. If the detector is already installed in the
junction box, go to step 6.

4. Guide the detector leads through the bottom conduit hub of the junction box, then
screw the mounting threads of the detector into the conduit hub.

5. Connect the detector leads to the terminal block in the junction box.

6. Guide a two-conductor, shielded cable or two wires in conduit through the top
conduit hub of the junction box. Use appropriate conduit fittings.

7. Connect the wires to the terminals opposite the detector leads.

65-2511RK/65-2512RK Oxygen Detector• 6

CAUTION: Leave the shield drain wire insulated and disconnected at the detector. You will

connect the opposite end of the cable’s drain wire at the controller.

8. Secure the junction box cover to the junction box.

9. Route the cable or wires in conduit leading from the detector through one of the
conduit hubs at the controller. Use appropriate conduit fittings.

10. Connect the wires to the appropriate controller detector terminal strip. See the
controller operator’s manual for wiring instructions.

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.

Green

(-)

Controller Oxygen
Detector Terminals

(+)

White

J-Box

Terminal Strip

White

Detector Wires

Green

Oxygen Detector

Figure 2: Wiring the Oxygen Detector to a Controller

65-2502RK/65-2510RK Oxygen Detector• 7

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, 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 Fresh Air Reading.”

Setting the Fresh Air Reading

CAUTION: If you suspect that the monitoring environment is not a fresh air environment, use

the zero air calibration cylinder to introduce “fresh air” to the detector and verify an
accurate fresh air reading.

1. Verify that the detector is in a fresh air environment (environment known to be of
normal oxygen content and free of toxic and combustible gasses).

2. Verify a reading of 20.9% oxygen at the controller.
If the display reading is 20.9% oxygen, start up is complete. The oxygen detector is in

normal operation. If the display reading is not 20.9% oxygen, continue with step 3.

3. Perform a fresh air adjustment operation at the controller. See the controller
operator’s manual for instructions.

65-2511RK/65-2512RK Oxygen Detector• 8

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 detector 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 operator’s manual for instructions 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. See the
calibration frequency discussion in the Calibration section to determine if a quarterly
calibration schedule fits your needs.

65-2502RK/65-2510RK Oxygen Detector• 9

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

operator’s 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 controller.

3. Remove the junction box cover.

4. Disconnect the detector leads from the terminal block inside the junction box. Note
the position of the color-coded leads as you remove them.

5. Unscrew the detector from the junction box.

6. Guide the detector leads of the replacement detector through the bottom conduit hub
of the junction box, then screw the mounting threads of the detector into the conduit
hub and tighten firmly.

7. Connect the detector leads to the terminal block in the same position as the leads you
removed in step 4.

8. Secure the junction box cover to the junction box.

9. Turn on power to the controller.

65-2511RK/65-2512RK Oxygen Detector• 10

Calibration

10. Turn on the controller.

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

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 calibration using a fixed flow regulator which has no on/
off knob and allows sample to flow as soon as it is screwed into a cylinder. RKI
Instruments, Inc. recommends using a 0.5 LPM (liters per minute) fixed flow regulator.

Calibration Frequency

Although there is no particular calibration frequency that is correct for all applications, a
calibration frequency of every 3 to 6 months is adequate for most applications. Unless
experience in a particular application dictates otherwise, RKI Instruments, Inc.
recommends a calibration frequency of every 3 months (quarterly).

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

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

procedure.

Setting the Fresh Air Reading

CAUTION: If you suspect the monitoring environment is not of normal oxygen content, 20.9%,

use the calibration kit and a zero air calibration cylinder to introduce “fresh air” to
the detector and verify an accurate fresh air setting.

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

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

into its calibration program or disable external alarms before continuing.

2. Verify that the detector is in a fresh air environment.

3. Follow the directions in the controller’s instruction manual for setting the fresh air
reading to 20.9% oxygen.

Setting the Zero Reading

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

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

NOTE : Do not screw the regulator into the calibration cylinder at this time.

65-2502RK/65-2510RK Oxygen Detector• 11

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

4. When the instructions call for exposing the detector to gas, normally 100% nitrogen,
screw the regulator into the cylinder and allow the gas to flow to the detector for 2
minutes before continuing with the instructions. The detector signal should be stable
after two minutes.

5. After setting the zero reading, unscrew the regulator from the cylinder and remove
the calibration cup from the detector.

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

sample tubing.

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

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

point, then unwanted alarms may occur.

7. Verify that the controller display reading increases and stabilizes at 20.9% oxygen.

8. Store the components of the calibration kit in a safe and convenient place.

Parts List

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)
18-0400RK-01 Junction box with spacers
65-2511RK Oxygen detector, conduit-mounting, capillary type, not including

junction box
65-2512RK Oxygen detector including junction box.
71-0109RK

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% nitrogen; 34-liter)

65-2511RK/65-2512RK Oxygen Detector Operator’s Manual (this

document)

81-1003RK Regulator, 0.5 liter/minute; continuous flow

81-1117RK Calibration cup

65-2511RK/65-2512RK Oxygen Detector• 12

(for 17- and 34-liter calibration cylinders)