RKI Instruments 65-2511RK User manual

www.rkiinstruments.com

65-2511RK/65-2512RK

Oxygen Detector

Operator’s Manual

Part Number: 71-0109RK

Revision: B

Released: 3/1/11

65-2511RK/65-2512RK Oxygen Detector

WARNING

Read and understand this instruction manual before operating

detector. Improper use of the detector could result in bodily harm

or death.

Periodic calibration and maintenance of the detector is essential

for proper operation and correct readings. Please calibrate and

maintain this detector regularly! Frequency of calibration

depends upon the type of use you have and the sensor types.

Typical calibration frequencies for most applications are between

3 and 6 months, but can be required more often or less often

based on your usage.

65-2511RK/65-2512RK Oxygen Detector

Product Warranty

RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free from defects in

materials, workmanship, and performance for a period of one year from date of shipment

from RKI Instruments, Inc. Any parts found defective within that period will be repaired

or replaced, at our option, free of charge. This warranty does not apply to those items

which by their nature are subject to deterioration or consumption in normal service, and

which must be cleaned, repaired, or replaced on a routine basis. Examples of such items

are:

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or

repair procedures not in accordance with the operator’s manual. This warranty indicates

the full extent of our liability, and we are not responsible for removal or replacement costs,

local repair costs, transportation costs, or contingent expenses incurred without our prior

approval.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER

WARRANTIES AND REPRESENTATIONS, EXPRESSED OR IMPLIED,

AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF

RKI INSTRUMENTS, INC. INCLUDING BUT NOT LIMITED TO, THE

WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS,

INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL

LOSS OR DAMAGE OF ANY KIND CONNECTED WITH THE USE OF

ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR

OPERATE PROPERLY.

This warranty covers instruments and parts sold to users by authorized distributors,

dealers, and representatives as appointed by RKI Instruments, Inc.

We do not assume indemnification for any accident or damage caused by the operation of

this gas monitor, and our warranty is limited to the replacement of parts or our complete

goods.

a) Absorbent cartridges d) Batteries

b) Pump diaphragms and valves e) Filter elements

c) Fuses

65-2511RK/65-2512RK Oxygen 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

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

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

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

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

65-2511RK/65-2512RK Oxygen Detector • 1

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.

WARNING: When using the 65-2511RK/65-2512RK, you must follow the instructions

and warnings in this manual to assure proper and safe operation of the

65-2511RK/65-2512RK and to minimize the risk of personal injury. Be sure

to maintain and periodically calibrate the 65-2511RK/65-2512RK as

described in this manual.

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

Accuracy ± 0.5% O2

Operating Temperature -20° C to 45° C

Output Millivolt (mV)

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

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 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 65-2511RK, 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.

65-2511RK/65-2512RK Oxygen Detector • 3

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 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

65-2511RK 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.

3.6

6.7 MAX

2.7

.75

Threads For

Calibration Cup

Installation

.38

Space

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

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

7. Secure the junction box cover to the junction box.

8. Route the cable or wires 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 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 65-2512RK 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.

(-)

(+) Controller Oxygen

Detector Terminals

J-Box

Terminal Strip

White

Green

Oxygen Detector

Detector Wire

Green

White

65-2511RK/65-2512RK Oxygen Detector • 5

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, 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

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

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

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.

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