RKI Instruments 82-5222 User manual

www.rkiinstruments.com
82-5222
24 VDC Pneumatic ESTOP
Operator’s Manual
Part Number: 71-0571
Revision: P1
Released: 8/13/21

2 • 82-5222
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 the 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. Parts must be returned to RKI Instruments, Inc. for repair or replacement. 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 instruction manual. This warranty indicates the full extend 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 only 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. Warranty
covers parts and labor performed at RKI Instruments, Inc. only, and does not cover field labor or
shipment of parts back to RKI.
a) Pump diaphragms and valves c) Batteries
b) Fuses d) Filter elements

82-5222 • 3
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
About the 82-5222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
External Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Internal Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Factory Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Making Tubing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 • 82-5222
Overview
This manual describes the 82-5222 emergency shutoff. It also describes how to install and start up the
device. A spare parts list at the end of this manual lists replacement parts.
About the 82-5222
The 82-5222 is a fixed-mounted device with a solenoid valve, relay, stack light, and emergency stop
button. It requires 24 VDC and compressed air to operate. The solenoid valve inside the 82-5222 is
field-plumbed via the “In” and “Out” ports to a user-supplied pneumatic device. When the emergency
stop button on the front of the housing door is pushed, the internal solenoid valve de-energizes and the
pneumatic line between the 82-5222 and the user-supplied pneumatic device depressurizes through the
vent port. A set of remote relay contacts may optionally be used to
de-energize the solenoid.
Specifications
Table 1 lists specifications for the sample drawing gas detector.
WARNING: When using the 82-5222, you must follow the instructions and warnings in this
manual to assure proper and safe operation of the 82-5222 and to minimize the risk of
personal injury.
Table 1: Specifications
Construction (housing) • PBT/PC blend
•NEMA4X
Dimensions 18.82 in. (478 mm) H x 8.09 in. (205 mm) W x 7.19 in. (183 mm) D
Weight 6.1 lbs.
Input Power for Device 24 VDC
“In” and “Out” Ports
Pressure Rating
160 psi

82-5222 • 5
Description
External Description
This section describes the external components of the 82-5222.
Figure 1: External Component Location
Housing
The 82-5222’s PBT/PC blend housing is weather- and corrosion-resistant. It is suitable for installation
where general purpose equipment is in use. The housing door is hinged on the left side and is secured
by two latches on the right side. A panel inside the housing allows for component installation and
mounting. Four mounting feet are attached to the back of the housing (one at each corner). The
mounting feet are used to install the housing to a wall.
One conduit hub on the bottom of the housing is for external wiring connections. Two compression
fittings for 1/4 inch OD rigid tubing allow for compressed air to be routed to and from the 82-5222.
One hose barb fitting for 1/4 inch ID flexible tubing allows for vented air to be routed away from the
82-5222, if desired.
Stack Light
Emergency Stop Button
1/4 inch OD Rigid Tubing "Out"
1/4 inch ID Flexible Tubing "Vent"
Housing
1/4 inch OD Rigid Tubing "In"
3/4 NPT Conduit Hub

6 • 82-5222
Emergency Stop Button
When the emergency stop button on the front of the 82-5222 is pushed, the internal solenoid valve de-
energizes which closes the “In” port and causes the pneumatic line between the 82-5222 and the user-
supplied pneumatic device to depressurize through the vent port.
Reset a pushed button by turning it clockwise.
Stack Light
The stack light installed on the top of the housing indicates the status of the solenoid valve’s power
line. When the light is green, the pneumatic line between the 82-5222 and the connected pneumatic
device is pressurized. When the light is red, the “In” port is closed and the pneumatic line between the
82-5222 and the connected pneumatic device depressurizes through the vent port.
Internal Description
This section describes the internal components of the 82-5222.
Figure 2: Internal Component Location
Relay
A DPDT relay installed on the right side of the 82-5222 controls the stack light’s LED color and also
controls the power to the solenoid valve.
_
INPUT
POWER
24 VDC
+
Solenoid Valve
Mounting Plate
FieldWiring
Terminal Strip
Fuse
TO ALARM
CONTACTS
1 NC 2
Emergency Stop
Button Connections
Relay

82-5222 • 7
Solenoid Valve
A 3-way solenoid valve installed on the left side of the 82-5222 controls the flow of connected
compressed air. When the solenoid is energized, the pneumatic line between the 82-5222 and the
connected pneumatic device is pressurized. When the solenoid de-energizes, it closes the “In” port and
depressurizes the pnematic line between the 82-5222 and the connected pneumatic device through the
vent port.
Emergeny Stop Button Connections
The emergency stop button’s wiring connections are visible on the back of the door. They are factory
wired to the Field Wiring Terminal Strip.
Fuse
A 250V, 1A slow blow fuse is installed in the power line that runs to the stack light. The fuse holder is
secured to the right side of the housing with a zip tie.
Field Wiring Terminal Strip
The Field Wiring Terminal Strip allows for a set of remote relay contacts to be wired into the system as
an additional control over the solenoid valve. A factory-installed jumper should be left installed if
remote relay contacts are not being wired to the terminal strip.
Installation
This sections describes how to mount and wire the 82-5222.
Mounting
1. Select the mounting site. When you select the mounting site, consider the following factors:
• Is a DC power source available?
• Is a vertical surface available to mount the 82-5222?
• Is there enough room to open the housing door, make tubing connections, and make wiring
connections at the bottom of the housing?
• Is the stack light visible?
• Is the location easily accessible in case of an emergency?
2. The 82-5222 is shipped with the mounting feet positioned under the housing. Loosen the screws
that secure the feet to the housing, rotate the feet to their mounting position as shown in Figure 3,
then tighten the screws.
3. Position the 82-5222 on the vertical mounting surface.

8 • 82-5222
4. Insert 3/16 in. screws through the mounting slots to secure the housing to the mounting surface.
Figure 3: Outline & Mounting Dimensions
7.19
8.09
6.04
Ø .23 x .3 slot, 4X
11.41
18.82

82-5222 • 9
Factory Wiring
The figure below shows factory wiring connections. These wiring connections should not need
adjustment.
Figure 4: Factory Wiring
1
5
Relay
NC
NO
4
8
9
NO
NC
Black
Black
C
Red
Red
IN PUT
POWER
24 VDC
_+
12
Red
C
Red
Green
Yellow
Red
Red
Green
1NC 2
Red
Not Used
Stack Light
TOALARM
CONTACTS
+13
Solenoid
Valve
Black
Emergency Stop
Button Contacts
-
14

10 • 82-5222
Field Wiring
This section describes how to wire 24 VDC to power the 82-5222 and how to wire a remote relay
contact into the 82-5222 (optional).
1. Turn off or unplug power to the 82-5222.
2. Open the housing door.
Power Wiring
3. Guide a 2-conductor cable or 2 wires in conduit through the conduit hub on the bottom of the
housing. Use appropriate conduit fittings and construction technique for the environmental rating
of the housing. The housing is rated NEMA 4X.
4. Connect one end of both wires to the + and - terminals of a 24 VDC power source.
5. Connect the other end of both wires to the appropriate “Input Power 24 VDC” terminal on the
Field Wiring Terminal Strip as shown in Figure 5 below.
Remote Relay Contact Wiring
Connecting the 82-5222 to a remote relay contact is is not necessary for operation. Connecting the
82-5222 to a remote relay contact provides another way to de-energize the solenoid valve and
depressurize the pneumatic line between the 82-5222 and the connected pneumatic device. If you do
connect the 82-5222 to a remote relay contact, the relay contact set used must be normally open and
the relay must be configured as normally energized.
6. Remove the jumper from the Field Wiring Terminal Strip.
NOTE: If you are not connecting a remote relay contact to the 82-5222, the jumper must stay
installed.
7. Guide a 2-conductor cable or 2 wires in conduit through the conduit hub on the bottom of the
82-5222 housing. Use appropriate conduit fittings and construction technique for the
environmental rating of the housing. The housing is rated NEMA 4X.
8. Connect the wires to the “To Alarm Contacts” terminals on the Field Wiring Terminal Strip.
9. Guide the other end of the wires to the normally open remote relay contact. Use appropriate
conduit fittings and construction technique for the environmental rating of the relay contact’s
housing. RKI’s controllers are rated NEMA 4X.
10. Connect the wires to the NO and C contacts on the remote relay that you want to use to control the
solenoid valve (as shown in Figure 5 below). When the relay contact is closed, the solenoid valve
is energized and the pneumatic line between the 82-5222 and the connected pneumatic device is
pressurized. When the relay contact opens, the the solenoid valve de-energizes, the “In” port
closes, and the pneumatic line between the 82-5222 and the pneumatic device depressurizes
through the vent port.
NOTE: The relay that you connect to the 82-5222 must be configured as normally energized.

82-5222 • 11
Figure 5: Field Wiring
11. Close the housing door.
NOTE: If remote relay contactsare not
wired to the Field Wiring Terminal
Strip, leave thejumper installed.
24 VDC
Power
Source
+
_
Field Wiring
Terminal
Strip
_+
INPUT
POWER
24 VDC
TO ALARM
CONTACTS
C
Relay Contacts
NO

12 • 82-5222
Making Tubing Connections
1. Connect a compressed air source up to a maximum of 160 psi to the compression fitting labelled
“In” using 1/4 inch OD stainless steel, copper, or aluminum tubing.
2. Connect the compression fitting labelled “Out” to the user-supplied pneumatic device using 1/4
inch OD stainless steel, copper, or aluminum tubing.
3. For each of the 82-5222’s compression fittings, hold the fitting still using a 5/8 inch open-end
wrench or an adjustable wrench and firmly tighten the nut with a 9/16 inch open-end wrench or an
adjustable wrench so the ferrules crimp onto the tubing and make a seal.
4. If desired, connect a piece of 1/4 inch ID flexible tubing to the hose barb labelled “Vent” and route
it away from the 82-5222.
1/4 inch ID Flexible Tubing "Vent" 1/4 inch OD Rigid Tubing "In"
1/4 inch OD Rigid Tubing "Out"
1/4 inch OD
rigid metal
tubing
Hold Still (5/8 inch)
Ferrule
Nut (9/16 inch)

82-5222 • 13
Start Up
1. Be sure the emergency stop button is not pushed. If it is pushed, turn it clockwise to reset it.
2. Turn on the compressed air source, power to the 82-5222, and power to the device whose relay
contact is wired to the 82-5222 (if used).
3. Power is immediately applied to the solenoid valve, the pneumatic line between the 82-5222 and
the connected pneumatic device pressurizes, and the green LED on the stack light turns on.
Operation
Normal Operation
During normal operation, the stack light is green, the solenoid valve is energized, and the pneumatic
line between the 82-5222 and the connected pneumatic device is pressurized.
Alarms
If the emergency stop button is pushed or if the remote relay contact opens (if used), the stack light
turns red, the solenoid valve de-energizes, the “In” port closes, and the pneumatic line between the
82-5222 and the connected pneumatic device depressurizes through the vent port.
Twist the emergency stop button clockwise to reset it and restore power to the solenoid valve. Reset a
remote relay contact alarm as described in the device’s manual.

14 • 82-5222
Replacing the Fuse
1. Turn off or disconnect power to the 82-5222.
2. Open the 82-5222 housing door.
3. Locate the fuse. It is in the power line shown below and is secured to the right side of the housing
with a zip tie.
Figure 6: Fuse Location
4. Cut the zip tie to access the fuse holder.
5. Unscrew the two halves of the fuse holder.
6. Remove the old fuse.
7. Install the new fuse.
8. Screw the two halves of the fuse holder back together.
9. Use a new zip tie to connect the fuse holder to the right side of the housing.
10. Close the housing door.
11. Plug in or connect power to the 82-5222.
8
1
5
C
-
4
912
14
Fuse
+
C
NC
NO
13

82-5222 • 15
Parts List
Table 2 lists replacement parts and accessories for the 82-5222.
Table 2: Parts List
Part Number Description
43-4143RK Fuse, 5 mm x 20 mm, 250V, 1A, slow blow
51-0210 Stack light, red/green, steady
71-0571 82-5222 Operator’s Manual (this document)