INSTRUCTION 0019-9166 COMBINED SERVICE MANUAL for: DIOXOR® II MONOXOR® II MONOXOR® II H (High Range) NONOXOR® II Rev. 7 – May 2010 Bacharach, Inc. 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, Dioxor, Monoxor, and Nonoxor are registered trademarks of Bacharach, Inc. Copyright © Bacharach 1997-2010, all rights reserved.
TABLE OF CONTENTS 1.0 SERVICE MANUAL CONTENTS.................................................................4 2.0 MAINTENANCE ............................................................................................5 2.1 2.2 2.3 2.4 2.5 2.6 3.0 Opening the Case..................................................................................5 Closing the Case....................................................................................6 Cleaning...............................................
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.
Single Gas Instrument Service Manual 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. 5.
Single Gas Instrument Service Manual 2.2 Closing the Case Equipment Needed: • Phillips-Head Screwdriver, No. 1 Procedure: CAUTION 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. 3.
Single Gas Instrument Service Manual 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 Screwdriver, 1/8" flat-blade Warm soapy water Allen Wrench, .05 in. • Clean rags • Cotton Swabs • Pipe cleaners Procedure: 1. Open the case as described in Section “2.1 Opening the Case.” 2.
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.
Single Gas Instrument Service Manual 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.
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.
Single Gas Instrument Service Manual 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" flat-blade Allen Wrench, .05 in. Replacement pump parts, as required Procedure: 1. Open the case as described in Section “2.1 Opening the Case.” 2.
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: WARNING! Perform this procedure in a well ventilated area. CO is toxic! 1.
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.
Single Gas Instrument Service Manual 4.0 TROUBLESHOOTING CHART Symptom No display when unit is switched on Backlight won't light Unit doesn't respond to gas (e.g., from calibration gas) LCD segments missing Page 14 Cause Remedy Batteries dead Replace batteries with four fresh “C” Alkaline cells. Batteries installed backwards Insert batteries correctly. Wait at least one minute before switching on unit to allow its PTC resistor to cool. P.C.B. defective Replace P.C.B. Refer to Section “2.
Single Gas Instrument Service Manual Symptom Erratic display Cause Remedy Low batteries Replace batteries with four fresh “C” Alkaline cells. Faulty Motor Break in a new Motor for at 30 minutes. Replace Motor Assembly. Refer to Section “2.6 Chamber Assembly Servicing.” Unit won't zero and/or span Instruction 0019-9166 Sensor connections loose or broken Check Sensor connections. See Fig 2-2. Sensor depleted or defective Replace Sensor. Refer to Section “2.4 Sensor Replacement.” P.C.B.
Single Gas Instrument Service Manual Symptom Bouncing display > ± 3 counts Cause Sensor connections loose Motor has excessive arcing in its carbon brush/commutator interface causing RFI Very little (<0.25" H2O) or no Chamber assembly screws loose draft indication on manometer dead headed into instrument Page 16 Remedy 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.
Single Gas Instrument Service Manual 5.0 REPLACEMENT PARTS Replacement parts for the instrument are listed below. Please refer to the appropriate figure(s) for part locations. 5.1 Probe Assembly (Fig 5-1) Item 1 -2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Part No. Probe Assembly, Standard Probe Assembly, Flexible (not shown) Probe Tube Probe Handle Screw, Phillips head, M3 x .
Single Gas Instrument Service Manual 5.2 Instrument Assembly (Figs 5-2 & 5-3) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Description Part No.
Single Gas Instrument Service Manual Figure 5-3. Replacement Parts, Back and Front Exploded Views Instruction 0019-9166 Bacharach, Inc.
5.3 Miscellaneous Parts and Accessories Description Calibration Kit Carbon Monoxide Gas Cylinder, 500 ppm Potentiometer adjustment tool Custom Carrying Case (1 Instrument) Custom Carrying Case (2 Instrument) Instruction Manual, (Dioxor II) Instruction Manual, (Monoxor II) Instruction Manual, (Nonoxor II) Instruction Manual, (Monoxor II H) Calibration Card Service Manual, (This Manual) Label, Carrying Case Probe Stop (for Securing ¼ Probe in a Flue or Stack) Warranty Card 5.
