Bacharach DIOXOR II, MONOXOR II, 0019-7038, NONOXOR II, MONOXOR II H Combined Service Manual

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INSTRUCTION 0019-9166

COMBINED SERVICE MANUAL for:

DIOXOR

MONOXOR® II

MONOXOR® II H (High Range)

NONOXOR® II

Rev. 7 – May 2010

621 Hunt Valley Circle, New Kensington, PA 15068

Phone: 1-800-736-4666 • Fax: 724-334-5001 • Web: www.mybacharach.com

Printed in the U,S.A.

Bacharach, Inc.

TABLE OF CONTENTS

1.0 SERVICE MANUAL CONTENTS.................................................................4

2.0 MAINTENANCE ............................................................................................5

2.1 Opening the Case..................................................................................5

2.2 Closing the Case....................................................................................6

2.3 Cleaning........................................................................................7

2.4 Sensor Replacement..............................................................................9

2.5 Printed Circuit Board Replacement.....................................................10

2.6 Chamber Assembly Servicing..............................................................11

3.0 SENSOR CALIBRATION............................................................................12

3.1 Monoxer II CO Calibration.................................................................12

3.2 Dioxor II SO2, Monoxor II H CO, and Nonoxor II NOx Calibration...13

4.0 TROUBLESHOOTING CHART ................................................................14

5.0 REPLACEMENT PARTS.............................................................................17

5.1 Probe Assembly .................................................................................17

5.2 Instrument Assembly ..........................................................................18

5.3 Miscellaneous Parts and Accessories.................................................20

5.4 BACHARACH Sales/Service Centers...............................................20

Single Gas Instrument Service Manual

1.0 SERVICE MANUAL CONTENTS

This manual contains the following service information for the . . .

DIOXOR II (Part No. 0019-7038 & 0019-7043)

MONOXOR II (Part No. 0019-7034 & 0019-7039)

MONOXOR II H (Part No. 0019-8015)

NONOXOR II (Part No. 0019-7036 & 0019-7042).

NOTE: The 0019-7039, 0019-7042, and 0019-7043 versions of these instruments do not contain a probe, all non-probe related functions remain the same in this instruction.

• Instrument maintenance, which includes information on how to:

• Open and close the case

• Clean the Fan Assembly and chamber assembly area

• Replace the sensor

• Replace the Printed Circuit Board (P.C.B.)

• Service the gas-sensing chamber assembly (chamber assembly)

• Sensor calibration

• Troubleshooting chart

• Replacement parts list

GENERAL NOTE

If excessive torque is applied to the instrument's fasteners, poor performance or damage to components may occur.

The torque speciﬁ cations are as follows:

Screws Torque

Sensor Mounting 4 - 8 oz. in. Motor Mounting 6-10 oz. in. Chamber Sealing 16-20 oz. in. Rear Cover/Case 18-24 oz. in. Fan Assembly 32-40 oz. in.

Page 4 Bacharach, Inc. Instruction 0019-9166

2.0 MAINTENANCE

2.1 Opening the Case

Equipment Needed:

• Phillips-head screwdriver, No. 1

Procedure:

1. Lay the instrument face down on a workbench; then detach the metal clip from the bottom of case and fold the elastic strap over top of the instrument (Fig 2-1).

2. Slide off battery cover.

3. Remove batteries.

4. Using a No. 1 Phillips-head screwdriver, remove the two screws from the rear of the case.

Single Gas Instrument Service Manual

Figure 2-1.

Opening and Closing the Case

5. Lift up the bottom portion of the rear case and slide it forward until the case clears the inlet port.

6. To gain better access to the components, remove the gas-sensing chamber assembly (Chamber Assembly) and the Printed Circuit Board (P.C.B.) from the front case by pulling them straight up from the front case (Fig 2 -2); then lay these items on your workbench.

Instruction 0019-9166 Bacharach, Inc. Page 5

Single Gas Instrument Service Manual

2.2 Closing the Case

Equipment Needed:

• Phillips-Head Screwdriver, No. 1

Procedure:

When replacing the P.C.B. and chamber assembly, the P.C.B. must be installed FIRST. The P.C.B. switches could be damaged if the P.C.B. is installed after the chamber assembly is in place.

1. Ensure that the P.C.B. is properly positioned face down over its locating-tab on the front case (Fig 2-2).

2. Properly position the chamber assembly between the ribs of the front case.

CAUTION

Figure 2-2.

P.C.B. and Chamber Assembly Removal and Installation

3. Slide the rear case over the inlet port and properly join the two case halves together.

4. Secure the case halves to each other using the two screws removed in Section 2.1, Step 4 (Tighten to 18–24 oz. in.).

5. Reinstall the batteries (observe proper battery polarity); replace the battery cover; and attach the elastic strap’s metal clip to the bottom of the instrument.

Page 6 Bacharach, Inc. Instruction 0019-9166

2.3 Cleaning

The inside of the chamber assembly is the only part of the instrument that needs to be cleaned. To clean the chamber assembly, proceed as follows:

Equipment Needed:

• Screwdriver, No. 1 Phillips head • Clean rags

• Screwdriver, 1/8" ﬂ at-blade • Cotton Swabs

• Warm soapy water • Pipe cleaners

• Allen Wrench, .05 in.

Procedure:

1. Open the case as described in Section “2.1 Opening the Case.”

2. Using a ﬂ at-blade screwdriver, remove the three screws and nuts that secure the Sensor to the chamber assembly; DO NOT remove the sensor wires. Then remove the Sensor along with its O-ring and Membrane from the chamber assembly.

Single Gas Instrument Service Manual

3. Using a No. 1 Phillips-head screwdriver, disassemble the chamber assembly by removing the two screws and nuts that secure the Chamber to the Motor Assembly

(Fig 2-3).

NOTE: Do not remove the Fan Assembly unless it's absolutely necessary for cleaning or repair purposes.

4. If it is necessary to remove the Fan Assembly, ﬁ rst loosen the set screw on the Fan Assembly with the .05 in. Allen wrench, and then pull off the assembly.

NOTE: It is not necessary to disassemble the Motor Assembly. If motor replacement is required, refer to Section 2.6, Step 5.

5. Clean the Fan Assembly, Chamber & Motor Assembly (see Fig 2-3) using cotton swabs and clean rags dampened with warm, soapy water. After cleaning, dry all parts with clean dry rags and cotton swabs.

NOTE: Replace, DO NOT CLEAN, the Membrane (Fig 2-2) if dirty.

6. Clean the Chamber’s inlet and outlet ports using pipe cleaners dipped in warm, soapy water. After cleaning, dry them with clean dry pipe cleaners.

7. Reassemble the chamber assembly as follows:

NOTE: DO NOT overtighten any screws; damage to plastic parts will result.

Instruction 0019-9166 Bacharach, Inc. Page 7

Single Gas Instrument Service Manual

a. If disassembled, push the Fan Assembly onto the Motor shaft until it seats

(Fig 2-3). Be sure the set screw (Fig 2-3A) is not screwed in so far that it prevents the adapter from seating fully. Tighten the set screw to approximately 32–40 ounce-inches using the .05 in. Allen wrench. Spin the Fan Assembly to be sure it will run in the chamber.

b. Mate and secure the Chamber and Motor Assembly together with the

two screws and nuts removed in Step 3 (Tighten to 16–20 oz. in.).

8. Reinstall the Membrane (mesh side toward the chamber assembly), O-ring, and Sensor on the chamber assembly (Fig 2-2); then secure the Sensor using the three screws and nuts removed in Step 2 (Tighten to 4–8 oz. in.).

9. Close the case as per Section “2.2 Closing the Case.”

Figure 2-3.

Chamber Assembly, Exploded View

Figure 2-3A.

Fan-blade assembly set screw

Page 8 Bacharach, Inc. Instruction 0019-9166

2.4 Sensor Replacement

When the instrument can no longer be spanned, as described in Section “3.0 Sensor Calibration,” the Sensor has reached the end of its useful life, and should be replaced. The life of a Sensor is typically two years. The Sensor may also need to be replaced if the instrument will not zero properly, or if erratic gas readings occur. Refer to Section “4.0 Troubleshooting Chart.”

Equipment Needed (Refer to Section “5.0 Replacement Parts” for Part Nos.):

• Phillips-head screwdriver, No. 1 • Replacement Sensor:

• Nutdriver, 4mm (5/32") • Dioxor II - SO

• Screwdriver, 1/8" ﬂ at blade • Monoxor II - CO

• O-Ring and Membrane, if required • Nonoxor II - NO

Procedure:

Burn hazard! The Sensors contain corrosive chemicals, DO NOT puncture or take the sensors apart.

Single Gas Instrument Service Manual

• Monoxor II H - CO

WARNING!

1. Open the case as described in Section “2.1 Opening the Case.”

2. Using a nutdriver, loosen the nuts that secure the sensor wires to the Sensor terminals R, S and C; then remove the wires. If the Sensor has pin and socket connections, simply pull the sockets from the sensor pins.

3. Using a ﬂ at-blade screwdriver, remove the three screws and nuts that secure the Sensor to the chamber assembly; then remove the Sensor along with its O-ring and Membrane from the chamber assembly.

4. Remove and discard of the old Sensor in accordance with local and federal regulations. DO NOT discard the sensor’s O-ring and Membrane, unless you intend to replace these items.

NOTE: Replace the O-ring if it looks deformed, and replace the Membrane if it is contaminated with oil or dirt. We recommend that both the O-ring and Membrane be replaced at the same time.

5. Remove the new Sensor from its shipping canister. Do not remove the shorting wire (across the R & S terminals) from the Sensor (SO2 & CO only, the NOX does not have a shorting wire) until you are ready to make the electrical connection.

6. Position the Membrane, O-ring, and new Sensor on the chamber assembly as per Fig 2-2. Ensure that the sensor terminals are positioned as shown. Secure these items to the chamber assembly using the screws and nuts removed in Step 3 (Torque to 4–8 oz. in.). DO NOT overtighten the screws!

7. Remove the shorting wire from the R & S terminals (SO2 & CO only). Connect the blue (S), red (R), and black (C) wires from the P.C.B. to their associated sensor terminals (See Fig 2-4). If the Sensor uses nuts to secure the

Sensor wires, DO NOT overtighten these connections!

8. Close the case as per Section “2.2 Closing the Case.”

9. Calibrate the new Sensor as per Section “3.0 Sensor Calibration.”

Instruction 0019-9166 Bacharach, Inc. Page 9

Single Gas Instrument Service Manual

2.5 Printed Circuit Board (P.C.B.) Replacement

Equipment Needed (Refer to Section “5.0 Replacement Parts” for Part Nos.):

• Phillips-head screwdriver, No. 1

• Printed Circuit Board (P.C.B.)

Procedure:

1. Open the case as described in Section “2.1 Opening the Case.”

2. Unplug the motor connector from the P.C.B.

3. Unplug the sensor connector from the P.C.B.

NOTE: (For SO2 & CO Sensors only) If the Sensor is not going to be immediately plugged into the new P.C.B., place a shorting wire between sensor terminals R and S.

4. Remove the Switch Covers from the old P.C.B. and place them on the new

5. Plug the motor connector into the P.C.B.

6. Remove the shorting wire from sensor terminals R & S (if installed); then

7. Close the case as per Section 2.2 Closing the Case.”

8. Calibrate the Sensor with the new P.C.B. as per Section “3.0 Sensor Calibra-

9. Discard the old P.C.B.

Figure 2-4.

Sensor & Motor Wiring Diagram

P.C.B., then replace the old P.C.B. with the new one.

plug the sensor connector into the P.C.B.

tion.”

Page 10 Bacharach, Inc. Instruction 0019-9166

2.6 Chamber Assembly Servicing

To disassemble the chamber assembly, proceed as follows:

Equipment Needed (Refer to Section “5.0 Replacement Parts” for Part Nos.):

• Screwdriver, Phillips head, No. 1

• Screwdriver, 1/8" ﬂ at-blade

• Allen Wrench, .05 in.

• Replacement pump parts, as required

Procedure:

1. Open the case as described in Section “2.1 Opening the Case.”

Single Gas Instrument Service Manual

3. Using a No. 1 Phillips-head screwdriver, disassemble the Chamber from the Motor Assembly (Fig 2-3).

4. To remove the Fan Assembly, refer to Section 2.3, Step 4.

5. If Motor replacement is required:

a. Unplug the motor connector from the circuit board and discard the Motor

Assembly.

b. Install a new Motor Assembly and connect the motor connector to the

circuit board.

NOTE: A newly installed Motor must be broken in by running it for at least 30 minutes. A Motor not broken in may cause erratic display readings.

6. Reassemble the chamber assembly with any replacement parts using Section

2.3, Step 7.

7. Reinstall the Membrane, O-ring, and Sensor using Section 2.3, Step 8.

8. Close the case as per Section “2.2 Closing the Case.”

Instruction 0019-9166 Bacharach, Inc. Page 11

Single Gas Instrument Service Manual

3.0 SENSOR CALIBRATION

3.1 Monoxor II CO Calibration

The following calibrates the MONOXOR II to a known concentration of carbon monoxide.

Equipment Needed (Refer to Section “5.0 Replacement Parts” for Part Nos.):

• Calibration Kit

• Carbon Monoxide Gas Cylinder, 500 ppm

• Potentiometer adjustment tool

Procedure:

Perform this procedure in a well ventilated area. CO is toxic!

1. Assemble the calibration equipment by connecting the Carbon Monoxide Gas Cylinder and the components of the Calibration Kit together as shown in Fig 3-1.

WARNING!

Figure 3-1.

Calibration Kit Setup

NOTE: DO NOT attach the calibration setup to the instrument at this

time.

2. Zero the instrument as follows:

a. Ensure instrument will be sampling CO-free (fresh) air in the following

steps.

NOTE: An indication that the instrument was not zeroed in fresh air

is when a large negative CO display appears when the instrument is moved into another area.

b. Set front panel POWER switch to ON.

Page 12 Bacharach, Inc. Instruction 0019-9166

Single Gas Instrument Service Manual

Important! Do not proceed with this calibration procedure if the instrument’s “LO BAT”

indicator is on. We recommend that the instrument be calibrated with a fresh set of batteries.

c. Wait until the instrument’s CO display settles down (approximately 1 minute); then, using

a potentiometer adjustment tool, turn the front panel ADJUST potentiometer (Fig 3-2) until the display shows 0 ±3 ppm. The display shows negative numbers for zeroing purposes.

Figure 3-2.

ADJUST & CO Span Adjustments

3. Connect the CO discharge hose of the calibration equipment to the Monoxor's probe tip; then open the CO cylinder regulator valve and adjust the regulator for a ﬂ owmeter indication of 1 to 2 SCFH.

4. Allow gas to ﬂ ow for 2 minutes.

5. Read the detected CO level on the instrument’s LCD. Then using a potentiometer adjustment tool, adjust the CO SPAN potentiometer until the LCD reading matches the gas cylinder’s concentration value within ±5 ppm.

6. Shut off the regulator and remove the CO discharge hose from the gas inlet port. Then while observing the displayed CO level, allow the instrument to run until the CO reading drops to zero.

NOTE: If after 5 minutes the CO reading stabilizes at some value other than zero, readjust the

ADJUST potentiometer for an LCD indica tion of ±3 ppm.

7. Set front panel POWER switch to OFF.

8. Disassemble the calibration-equipment setup and store the components in the calibration kit’s carrying case.

3.2 Dioxor SO2, Monoxor II H CO, and Nonoxor NOX Calibration

The presence of SO2 and NOX gas in small amounts, and CO gas in larger amounts, can be very toxic. Calibration at a Bacharach Sales/Service Center is recommended (See Section “5.4 Bacharach Sales/ Service Centers” to ﬁ nd the nearest center). If you have a facility that is properly equipped to handle toxic gas (i.e.. fume hoods, self contained breathing apparatus etc.), we would be glad to suggest a calibration method.

Instruction 0019-9166 Bacharach, Inc. Page 13

Single Gas Instrument Service Manual

4.0 TROUBLESHOOTING CHART

Symptom Cause Remedy

No display when unit is switched on

Backlight won't light

Unit doesn't respond to gas (e.g., from calibration gas)

Batteries dead

Batteries installed backwards

P.C.B. defective

Backlight or its switch is defective

Sensor connections loose or broken

Sensor Membrane blocked with water or dirt

Replace batteries with four fresh “C” Alkaline cells.

Insert batteries correctly. Wait at least one minute before switching on unit to allow its PTC resistor to cool.

Replace P.C.B. Refer to Section “2.5 Printed Circuit Board Replacement.”

Check Sensor connections (Fig. 2-2).

Remove Sensor and replace its Membrane. See Fig. 2-2.

LCD segments missing

Sensor depleted or defective

P.C.B. defective

LCD loose or defective

P.C.B. defective

Replace Sensor. Refer to Section “2.4 Sensor Replacement.”

Replace P.C.B. Refer to Section “2.5 Printed Circuit Board Replacement.”

Carefully re-seat LCD in its socket. If segments are still missing, replace LCD.

Replace P.C.B. Refer to Section “2.5 Printed Circuit Board Replacement.”

Page 14 Bacharach, Inc. Instruction 0019-9166

Single Gas Instrument Service Manual

Symptom Cause Remedy

Erratic display

Unit won't zero and/or span

Low batteries

Faulty Motor

Sensor connections loose or broken

Sensor depleted or defective

P.C.B. defective

Too much gas present to zero

Replace batteries with four fresh “C” Alkaline cells.

Break in a new Motor for at 30 minutes.

Replace Motor Assembly. Refer to Section “2.6 Chamber Assembly Servicing.”

Check Sensor connections. See Fig 2-2.

Replace Sensor. Refer to Section “2.4 Sensor Replacement.”

Replace P.C.B. Refer to Section “2.5 Printed Circuit Board Replacement.”

Move unit into an area known to be gas free.

Probe kinked or blocked preventing gas ﬂ ow

Sensor connections loose or broken

Sensor depleted or defective

P.C.B. defective

Unkink or Replace Probe.

Check Sensor connections. See Fig 2-2.

Replace Sensor. Refer to Section “2.4 Sensor Replacement.”

Replace P.C.B. Refer to Section “2.5 Printed Circuit Board Replacement.”

Instruction 0019-9166 Bacharach, Inc. Page 15

Single Gas Instrument Service Manual

Symptom Cause Remedy

Bouncing display > ± 3 counts

Very little (<0.25" H2O) or no draft indication on manometer dead headed into instrument

Sensor connections loose

Motor has excessive arcing in its carbon brush/commutator interface causing RFI

Chamber assembly screws loose

Fan-blade Assembly loose

Inlet and/or outlet port(s) blocked

Check Sensor connections. See Fig 2-2.

Run Motor for at least 3 hours to wear away arc spots. If display still bounces, replace Motor Assembly. Refer to Section “2.6 Chamber Assembly Servicing.”

Tighten screws. Refer to Section “2.6 Chamber Assembly Servicing.”

Open chamber assembly and ensure that Fan-blade Assembly is mounted on Motor shaft. Refer to Section “2.6 Chamber Assembly Servicing.”

Clean ports. Refer to Section “2.3 Cleaning.”

Motor connections loose

Motor defective

P.C.B. defective

Reconnect Motor leads. Refer to Section "2.6 Chamber Assembly Servicing."

Check operation of Motor. If motor is receiving power but isn’t turning, replace Motor Assembly. Refer to Section “2.6 Chamber Assembly Servicing.”

Replace P.C.B. Refer to Section “2.5 Printed Circuit Board Replacement.”

Page 16 Bacharach, Inc. Instruction 0019-9166

5.0 REPLACEMENT PARTS

Replacement parts for the instrument are listed below. Please refer to the appropriate ﬁ gure(s) for part locations.

5.1 Probe Assembly (Fig 5-1)

Item Description Part No.

1 Probe Assembly, Standard 0019-3076

-- Probe Assembly, Flexible (not shown) 0019-3104 2 Probe Tube 0019-3073 3 Probe Handle 0019-3017 4 Screw, Phillips head, M3 x .5 x 8 mm 0501-3806 5 Tubing, 5/16 OD X 3/16 ID 0003-6109 6 Filter Saturator Bushing 0011-0074 7 Filter Packing 0011-0121 8 Filter Tube 0011-0130 9 Front Ferrule 0003-2024 10 Rear Ferrule 0003-2025 11 Knurled Nut 0003-2023 12 Compression Fitting 0003-2021 13 Barbed Fitting 0003-6164 14 Extended Adapter Block 0019-3072 15 Connector Tube 0011-0070

Single Gas Instrument Service Manual

Figure 5-1. Standard Probe Assembly

Instruction 0019-9166 Bacharach, Inc. Page 17

Single Gas Instrument Service Manual

5.2 Instrument Assembly (Figs 5-2 & 5-3)

Item Description Part No.

1 Adapter, Motor Shaft 0024-0412 2 Battery Clip, push on 0004-3113 3 Battery Cover with Foam Pad 0019-3029 4 Chamber 0019-3090 5 Front Cover w/Display Window (Dioxor II) 0019-3079 Front Cover w/Display Window (Monoxor II) 0019-3055 Front Cover w/Display Window (Nonoxor II) 0019-3078 Front Cover (Monoxor II H) (order with 0019-0437) 0019-3014 Display Window (Monoxor II H) (order with 0019-3014) 0019-0437 6 (Not Used) 7 Fan-Blade Assembly 0019-3013 8 LCD 0004-3700 9 Motor Assembly 0019-3063 10 Nut, Hex M2 x .4 0502-0007 11 O-Ring and Membrane 0024-0520 12 Printed Circuit Board Assy. (Dioxor II) 0019-3022 Printed Circuit Board Assy. (Monoxor II) 0019-3012 Printed Circuit Board Assy. (Nonoxor II) 0019-3020 Printed Circuit Board Assy. (Monoxor II H) 0019-3094 13 PTC Resistor 0204-9427 14 Rear Case w/ Label (Dioxor II) 0019-3082 Rear Case w/ Label (Monoxor II) 0019-3053 Rear Case w/ Label (Nonoxor II) 0019-3081 Rear Case (Monoxor II H) (order with 51-2347) 0019-3008 Label (Monoxor II H) (order with 0019-3008) 0051-2347 15 Retaining Ring 0002-2675 16 Screw, Cheese head, M2 x .4 x 30 mm 0501-3807 17 Screw, Phillips head, M2 x .4 x 6 mm 0501-3803 18 Screw, Phillips head, M3 x .5 x 8 mm 0501-3806 19 Sensor, SO2 (Dioxor II) 0019-8002 Sensor, CO (Monoxor II) 0024-0498 Sensor, ,NOX (Nonoxor II) 0019-8001 Sensor, CO (Monoxor II H) 0019-8016 20 Set Screw, #4-40 x 1/8 LG 0002-0001 21 Strap 0019-3028 22 Strap Clip 0019-3030 23 Strap Retainer 0019-3027 24 Switch Cover 0019-3021

Figure 5-2. Replacement Parts, Chamber Assembly Exploded View

Page 18 Bacharach, Inc. Instruction 0019-9166

Figure 5-3.

Replacement Parts, Back and Front Exploded Views

Single Gas Instrument Service Manual

Instruction 0019-9166 Bacharach, Inc. Page 19

5.3 Miscellaneous Parts and Accessories

Description Part No.

Calibration Kit 0024-7059 Carbon Monoxide Gas Cylinder, 500 ppm 0024-0492 Potentiometer adjustment tool 0006-9456 Custom Carrying Case (1 Instrument) 0019-0377 Custom Carrying Case (2 Instrument) 0019-3040 Instruction Manual, (Dioxor II) 0019-9121 Instruction Manual, (Monoxor II) 0019-9113 Instruction Manual, (Nonoxor II) 0019-9120 Instruction Manual, (Monoxor II H) 0019-9180 Calibration Card 0019-9150 Service Manual, (This Manual) 0019-9166 Label, Carrying Case 0019-3077 Probe Stop (for Securing ¼ Probe in a Flue or Stack) 0024-0434 Warranty Card 0006-8825

5.4 BACHARACH Sales/Service Centers

United States

Bacharach, Inc. 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 E-mail: help@mybacharach.com

Canada

Bacharach of Canada, Inc. 20 Amber St. Unit #7 Markham, Ontario L3R SP4 Canada Phone: 905-470-8985 Fax: 905-470-8963 Email: bachcan@idirect.com

Bacharach DIOXOR II, MONOXOR II, 0019-7038, NONOXOR II, MONOXOR II H Combined Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual