RKI Instruments 65-2302 User manual

www.rkiinstruments.com
65-2302/65-2303
CT-7 Series
Toxic Detector
Operator’s Manual
Part Number: 71-0422
Revision: 0
Released: 6/26/18

65-2302/65-2303 Toxic 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.

65-2302/65-2303 Toxic 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

65-2302/65-2303 Toxic Detector
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
65-2302 Toxic Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting the Toxic Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiring the Toxic Detector to a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Setting the Zero (Fresh Air) Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacing Components of the Toxic Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Special Note About Calibrating a ClO2Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting the Zero (Fresh Air) Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Setting the Response Reading (Span) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Returning to Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

65-2302/65-2303 Toxic Detector • 1
Overview
This manual describes the 65-2302 and 65-2303 toxic detectors. This manual also describes
how to install, start up, maintain, and calibrate the toxic detector when used with a gas
monitoring controller. A parts list at the end of this manual lists replacement parts and
accessories for the toxic detector.
The 65-2303 toxic detector includes the 65-2302 toxic detector and a junction box.
The 65-2302 toxic detector does not include a junction box and is normally mounted in one
of a controller’s conduit hubs. If you are using a 65-2302 toxic detector, disregard all
references to the junction box and junction box terminal strip.
The 65-2302 and 65-2303 detectors can be used for various target gases which are listed in
Table 1 below. For a particular target gas, the part number of the toxic detector will be of
the format 65-2302-XXX or 65-2303-XXX. For example, 65-2302-CLO2 is for chlorine
dioxide (ClO2) detection.
Specifications
WARNING: Do not use this product in a manner not specified in this instruction
manual.
Table 1 lists specifications for the various 65-2302/65-2303 toxic detectors.
WARNING: When using the 65-2302/65-2303, you must follow the instructions and
warnings in this manual to assure proper and safe operation of the
65-2302/65-2303 and to minimize the risk of personal injury. Be sure to
maintain and periodically calibrate the 65-2302/65-2303 as described in
this manual.
Table 1: Specifications
Target Gas and Detection Range 65-2302-CL2/65-2303-CL2: Chlorine (Cl2) 0 - 3.00 ppm
65-2302-CL2-05/65-2303-CL2-05: Chlorine (Cl2) 0 - 5.00 ppm
65-2302-CL2-10/65-2303-CL2-10: Chlorine (Cl2) 0 - 10.0 ppm
65-2302-CLO2/65-2303-CLO2: Chlorine Dioxide (ClO2) 0 - 1.00 ppm
Sampling Method Diffusion
Accuracy ± 10% of reading or ± 5% of full scale (whichever is greater)
Response Time T90 in 60 seconds
Operating Temperature &
Humidity -4°F to 104°F (-20°C to 40°C)

2 • 65-2302/65-2303 Toxic Detector
Description
This section describes the components of the 65-2302 and 65-2303. The 65-2303 includes
the 65-2302 toxic detector and a junction box. The 65-2302 does not include a junction box.
Figure 1 below shows the components of the 65-2303.
Figure 1: 65-2303 Component Location
65-2302 Toxic Detector
The 65-2302 toxic detector consists of the detector housing body, detector housing cap, cap
gasket, and the plug-in sensor.
Figure 2: 65-2302 Toxic Detector Component Location
3/4 NPT Conduit Hub
Detector
Junction Box
Plug-in Sensor
(different for each detector type)
Detector
Housing Cap
VersaporR Membrane
Detector Housing Body
(different for each detector type)
Cap Gasket

65-2302/65-2303 Toxic Detector • 3
Detector Housing Body
The detector housing body protects the electronic components within the housing. Use the
mounting threads at the top of the housing to screw the detector into a 3/4” NPT hub.
Two wires extend from the top of the detector housing body. Use these wires to connect
the detector to a controller. One of the wires is black and one of the wires is color-coded
depending on the detector type. See Figure 4 on page 5 for the color code assignments.
The housing body includes a four-socket pattern at the bottom of the housing body. The
plug-in sensor mates to this socket pattern. A pre-amplifier located between the sockets
and the two wires conditions the sensor’s signal before the signal reaches the controller.
Each plug-in sensor type (Cl2for example) requires a different pre-amplifier, so there is a
different detector housing body for each gas type.
Housing Cap and Cap Gasket
The housing cap screws onto the detector housing. It retains the sensor and protects it
from damage. A foam gasket inside the housing cap seals against the face of the sensor
when the cap is screwed on the housing body. Unscrew the detector cap to access the
sensor for replacement. A cap gasket seals the interface between the housing and cap.
Plug-in Sensor
The plug-in sensor is secured in the detector assembly by the housing cap. There is a
different sensor for each target gas. Through a series of chemical and electrical reactions,
the sensor produces an electrical output that corresponds to the detection range of the
sensor. A VersaporR membrane is installed on the sensor face for protection from water
and debris.
Junction Box
The junction box protects the detector wiring connections and allows you to install the
toxic detector at a mounting site that is remote from a controller. Two conduit hubs allow
you to mount the toxic 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 connections. 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 toxic detector in the monitoring
environment and wire the detector to a controller.
Mounting the Toxic Detector
NOTE: If you are installing a 65-2302, 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 65-2303 includes a
junction box as shown in Figure 3 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

4 • 65-2302/65-2303 Toxic Detector
procedures.
• Select a site where the target gas is likely to be found first.
NOTE: If your application does not require a specific mounting site, mount the detector
at approximately breathing level.
Figure 3: Outline & Mounting Dimensions, 65-2302 & 65-2303
2. At the mounting site you select, hang or mount the junction box with the detector
facing down (see Figure 3).
CAUTION: Mount the toxic detector with the detector facing down (see Figure 3.)
Wiring the Toxic Detector to a Controller
WARNING: Always verify that power to the controller is OFF before you make wiring
connections.
1. Turn off the controller.
2. Turn off or unplug 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, connect the detector’s color-coded
and black wires to the appropriate controller detector terminals (see Figure 4 for the
color coding of the non-black wire) and skip to the Startup Section.
.75 .38
Rubber
Spacer, 3X
3.10
3.65
Detector
7.30 .25 3/4" NPT
+
Ø1.75
11/2-20Threadfor
Calibration Cup
65-2302 65-2303
Junction
Box
11/2-20Threadfor
Calibration Cup
3/4 NPT
Conduit Hub
1.22
.75
6.70 Max

65-2302/65-2303 Toxic Detector • 5
4. Remove the junction box cover.
5. Guide a two-conductor, shielded cable or two wires in conduit through the unused
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.
6. Connect the two wires to the detector using the terminal block.
CAUTION: If using shielded cable, leave the 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 leading from the toxic detector through one of the conduit
hubs at the controller housing. 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 applicable controller terminal strip. See the controller
operator’s manual and the controller’s detector head specification sheet for the
65-2302 or 65-2303 detector.
Figure 4: Wiring the Toxic 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.
11. Reinstall the junction box cover.
(+) See Table
S
+
Controller Housing
Controller Detector Terminals,
Typical Designations
Gas TypeTable
CL2 yellow
CL2-05 yellow
CL2-10 yellow
CLO2 violet
Gas Type + Wire
0-3ppmCl2
Shielded
Cable
Black (S)
Detector
Terminal Strip
0 - 10 ppm Cl2
0-5ppmCl2

6 • 65-2302/65-2303 Toxic Detector
Start Up
This section describes procedures to start up the toxic 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 15 minutes before you continue with the next
section, “Setting the Zero Reading”.
Setting the Zero (Fresh Air) Reading
CAUTION: If you suspect the presence of the target gas in the monitoring environment, use the
calibration kit and a zero air calibration cylinder to introduce “fresh air” to the toxic
detector and verify an accurate zero setting.
CAUTION: Allow the detector to warm up for 15 minutes before setting the zero reading.
1. Verify a reading of 0 ppm at the controller.
If the display reading is 0 ppm, start up is complete. The toxic detector is in normal
operation.
If the display reading is not 0 ppm, continue with step 2 or step 3, depending on the
type of environment the detector is installed in.
2. For a fresh air environment (an environment known to be free of toxic and
combustible gases, and of normal oxygen content, 20.9%), set the zero reading
according to the controller operator’s manual.
3. For a non-fresh air environment:
a. Screw the calibration cup onto the bottom of the detector.
b. Screw the regulator into the zero air calibration cylinder.
c. Use the sample tubing to connect the regulator to the calibration cup.
d. Follow the instructions in the controller operator’s manual for setting the zero
reading.
e. When the instructions call for applying zero air to the detector, turn the
regulator’s on/off knob counterclockwise to open it. Gas will begin to flow.
f. Allow the gas to flow for two minutes.
g. Set the fresh air reading according to the controller operator’s manual.
h. Turn the regulator’s on/off knob clockwise to close it.
i. Unscrew the regulator from the calibration cylinder.