RKI Instruments 65-2515RK User Manual

65-2515RK

Oxygen Detector

Operator’ s Manual

Part Number: 71-0137RK

Revision: 0

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.

65-2515RK Oxygen Detector

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.

65-2515RK Oxygen Detector

Table of Contents

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

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

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

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

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Mounting the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Wiring the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

Verifying/Setting the Fresh Air Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Replacing the Oxygen Plug-in Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Replacing the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setting the Fresh Air Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setting the Zero Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

65-2515RK Oxygen Detector

Overview

!

This manual describes the 65-2515RK oxygen detector (internal amplifier type). This
manual also describes how to install, start up, maintain, and calibrate the detector when
used with a gas monitoring con troller. A parts list at the end of this manual lists
replacement parts and accessories for the oxygen detector.

Specifications

Table 1 lists specifications for the 65-2515RK oxygen detector.

Table 1: 65-2515RK Specifications

Target Gas Oxygen
Sampling Method Diffusion
Detection Range 0 - 25.0% oxygen
Accuracy ± 0.5% O

Oxygen Detector Signal Output 0 mV at 0% volume oxygen nominal

18 mV at 25% oxygen nominal
Response Time 90% in 30 seconds
Area Classification Explosionproof for Class I, Groups B, C, and D
Temperature Code T6
Installation Category Installation Category 1. Signal level, special equipm ent or parts of

equipment, telecommunication, electronic, etc., with smaller

transient overvoltages than Installati on Category (Overvoltage

Category) II (ref. IEC 664).
Operating Temperature -20° C to 45° C

NOTE: The following symbol on the detector label is a caution to the user to refer to this

documentation for installation and operation instructions:

W ARNING: When using the 65-2515RK, you must follow the instructions and warnings

in this manual to assure proper and safe operation of the 65-2515RK and to
minimize the risk of personal injury. Be sure to maintain and period ically
calibrate the 65-2515RK as described in this manual.

2

65-2515RK Oxygen De tec tor • 1

Description

This section describes the components of the 65-2515RK. It consists of the oxygen detector
and the junction box

Oxygen Detector

The oxygen detector consists of the detector housing and the plug-in sensor.

Detector
Housing Body

Cap Gasket

Oxygen Sensor

Detector Housing
Cap

Flame Arrestor
Guard

Figure 1: Oxygen Detector Component Location

Detector Housing

The detector housing protects the sensing components within the housing. Use the
mounting threads at the top of the housi ng to screw the oxygen detector into the bottom
conduit hub of the junction box. Use the removable cap near the bottom of the housing to
access the sensor for maintenance or replacement. The cap protects the sensor from
damage and includes a flame arrestor which contains any sparks th at may occur within
the detector housing. A cap gasket seals the interface between the housing body and cap.
The flame arrestor guard protects the flame arrestor from impact damage and is
permanently bonded to the cap.

Two color coded wi res extend from the top of the detector housing. Use these wires to
connect the oxygen detector to a controller via the terminal block in the junction box. The
detector housing includes two sockets installed on a circuit board. These sockets accept
the plug-in s ensor’s two pins to secure t he s e nsor within the detector housing. The circuit
board with the sockets conditions the sensor’s signal before it exits the detector housing
via the two color coded wires.

Plug-In Sensor

The plug-in sensor plugs into a circuit board in the detector housing with two pins and is
retained by the cap. Through a series of chemical and electrical reactions, the sensor
produces an electrical output that is proportional to the detection range of the oxygen
detector.

2 • 65-2515RK Oxygen Detector

Installation

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 junction box and route 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.

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

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.

2.7

3/4 NPT Conduit
Hub

.75

.38

3.2 Max

Rubber Spacers,3X

8.35 Max

3.62

1 1/2 -20 Thr ead for

Calibration Cup

Figure 2: 65-2515RK Outline & Mounting Dimensions

65-2515RK Oxygen De tec tor • 3

NOTE: The oxygen detector in the 65-2515RK is normally provided with an Adalet

XIHSCFC3 junction box rated explosion proof for Class I, Groups B, C, and D.
This combination is shown in Figure 2 above. Any junction box with an internal
volume less than or equal to 69 cubic inches and rated explosion proof fo r Class I,
Groups B, C, and D may be used for this detector.

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

facing down (see Figure 2).

Wiring the Oxygen Detector to a Controller

WARNING: Always verify that the power source is off before you make wiring

connections.

Cable Shield

Controller

OxygenDetector

Terminals

Green (-)
White (+)

Controller Housing

Terminal Strip

White

Green

Oxygen Detector

Figure 3: Wiring the Oxygen Detector to a Controller

1. Turn off the controlle r.

2. Turn off or unplug power to the controlle r.

3. Remove the junction box cover.

4. Guide a two-conductor, shielded cable or two wires in conduit through the unused
conduit hub of the junction box.

4 • 65-2515RK Oxygen Detector

WARNING: To maintain the explosion proof classification of the oxygen detector/

junction box combination, a conduit seal must be used within 18 inches of
the junction box conduit hu b used for wiring to the controller.

5. Connect the wires to the terminals opposite the detector leads using the terminal strip
in the junction box.

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

detector. You will connect the op posite end of the cable’s drain wire at the controller.

6. Reinstall the junction box cover to the junction box.

7. Route the cable or wires leading fro m th e oxygen detector through one of the conduit
hubs at the controller housing.

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.

8. Connect the wires to the applicable controller terminal strip as shown in Figure 3
above. See the controller operator’s manual and the controller’s detector head
specification sheet for wiring information specific to a controller.

9. 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.

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 operator’s 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 op erating 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, “Verifying/Setting the Fresh Air Reading”.

Verifying/Setting the Fresh Air Reading

WARNING: Do not remove the detector housing cap or junction box cover while the

circuits are energized unless the area is deter mined to be non-hazardous.
Keep the detector housing cap and junction box cover tightly closed during
operation.

65-2515RK Oxygen De tec tor • 5

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 air using a calibration kit that includes a
calibration cup, calibration gas, sample tubing, and a fixed flow regulator with an on/o ff
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 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 disassem ble the calibration kit.

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

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

10. Store the components of the calibration kit in a safe and conven ient place.

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

If the display reading is not 20.9% oxygen, set the fresh air reading according to the
controller’s operator’s manual.

the sample tubing connected to the regulator and the calibration cup.

detector.

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

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

test procedure.

6 • 65-2515RK Oxygen Detector

NOTE: Performing a respon se test on the oxygen dete ctor 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 dis play reading is 20.9% oxygen.
If the controller reading is not 20.9% oxygen, set the fresh air reading, then continue

this procedure. See “Calibration” on page 10 and the controller operator’s manual for
instructions to set the fresh air reading.

3. Exhale into the bottom of th e 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

“Calibration” on page 10.

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

Quarterly

Calibrate the detector as described in “Calibration” on page 10.

65-2515RK Oxygen De tec tor • 7

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 encounte r 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.

• The detector wiring is
disconnected or
misconnected.

• The plug-in oxygen
sensor is not properly
installed.

• The detector is
malfunctioning.

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

• The plug-in sensor is
malfunctioning.

1. Verify that the detector wiring is
correct and secure.

2. Confirm that the plug-in oxygen
sensor inside the detector housing is
installed properl y.

3. Calibrate the det ect or.

4. If the fail condition continues, replace
the plug-in oxygen sensor.

5. 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 plug-in sensor.

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

Replacing the Oxygen Plug-in Sensor

1. Turn off the controlle r.

2. Turn off or unplug incoming power to the controller.

3. Unscrew the detector housing cap from the detector housing.

4. Unplug and remove the oxyge n sensor.

5. Carefully plug the replacement sensor into the socket pattern that is located in the top
section of the detector housing.

NOTE: Match the sensor’s male pins with the two female sockets as you plug the sensor

into the sockets.

6. Screw the detector housing cap onto the detector housing.

7. Turn on or plug in incoming power to the controller.

8 • 65-2515RK Oxygen Detector

8. Turn on the controller.

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

next step.

9. Calibrate the replacement sensor as described in “Calibration” on page 10.

Replacing the Oxygen Detector

NOTE: In most cases, it is only necessary to replace the plug-in oxygen sensor.

1. Turn off the controlle r.

2. Turn off or unplug incoming power to the controller.

3. Remove the junction box cover.

4. Disconnect the detector leads from the terminal block inside the junction bo x. 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.

7. Wire the detector leads to the terminal block in the same position a s the leads you
removed in step 4.

8. Reinstall the junction box cover.

9. Turn on or plug in incoming power to the controller.

10. Turn on the controller.

CAUTION: Allow the replacement detector to warm up for 5 minutes before y o u c o ntinue with

the next step.

11. Calibrate the replacement detector as described in “Calibration” on page 10.

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 mo st 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 a re minima l 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.

65-2515RK Oxygen De tec tor • 9

Calibration

This section describes how to calibrate the oxygen detector. It includes procedures to
prepare for calibration, set the fr esh air r eading, set the zero r eading, and return to normal
operation. It describes calibration 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.

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

procedure.

Prepari ng for Ca libration

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

controller into its calibration program or disable external alarms before
calibrating.

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.

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 zero reading.

4. Put the controller into its calibration program.

Setting the Fresh Air Reading

1. Follow the directions in the controller operator’s manual for setting the fresh air
reading.

2. When the instructions call for applying z e ro air to the detector, turn the regulator’s
on/off knob counterclockwise to open it. Zero air will begin to flow.

3. Allow the gas to flow for two 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.

Setting the Zero Reading

1. Screw the regulator into the calibration gas cylinder, normally 100% nitrogen.

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 ga s, normally 100% nitrogen,
turn the regulator’s on/off knob counterclockwise to open it. Gas will begin to flow.

4. Allow gas to flow to the detector for two minut es .

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

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

10 • 65-2515RK Oxygen Detector

Parts List

7. Unscrew the regulator from the cylinder.

8. Remove the calibration cup from the detector. For convenience, leave the calibration
cup and regulator connected by the sample tubing.

Returning to Normal Operation

1. Allow about 45 seconds for the oxygen reading to incr ease above the de creasing alarm
point and 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.

2. Verify that the co ntroller dis p lay reading increases and stabilizes at 20.9% oxygen.

3. Store the components 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)
18-0400RK-01 Junction box with spacers
65-1025RK Oxygen replacement sensor, plug-in
65-2514RK Oxygen replacement detector assembly (includes plug-in sensor),

CSA classified (does not include junction box)
65-2515RK Oxygen detector/junction box, CSA classified
71-0137RK 65-2515RK Oxygen Detector Oper ator’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 C alibration cylinder (100% nitroge n; 34-liter)
81-1050RK Regulator with gauge and knob, 0.5 LPM, for 17- and 34-liter steel

81-1117RK Calibration cup

calibration cylinders

65-2515RK Oxygen D ete ct or • 1 1