Bacharach DIOXOR II Manuale utente

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.

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 ChamberAssembly 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

Page 4 Bacharach, Inc. Instruction 0019-9166

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 speciﬁcations 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.

Single Gas Instrument Service Manual

Instruction 0019-9166 Bacharach, Inc. Page 5

2.0 MAINTENANCE

2.1 Opening the Case

Figure 2-1.

Opening and

Closing 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. 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 as-

sembly (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.

Single Gas Instrument Service Manual

Page 6 Bacharach, Inc. Instruction 0019-9166

2.2 Closing the Case

Figure 2-2.

P.C.B. and

Chamber Assem-

bly

Removal and

Installation

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. 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 Sec-

tion 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 instru-

ment.

Single Gas Instrument Service Manual

Instruction 0019-9166 Bacharach, Inc. Page 7

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" ﬂat-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 ﬂat-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.

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 neces-

sary for cleaning or repair purposes.

4. If it is necessary to remove the Fan Assembly, ﬁrst loosen the set screw on

the Fan Assembly with the .05 in. Allen wrench, and then pull off the assem-

bly.

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 clean-

ing, 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.

Single Gas Instrument Service Manual

Page 8 Bacharach, Inc. Instruction 0019-9166

Figure 2-3.

Chamber As-

sembly, Exploded

View

Figure 2-3A.

Fan-blade assem-

bly set screw

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 approxi-

mately 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.”

Single Gas Instrument Service Manual

Instruction 0019-9166 Bacharach, Inc. Page 9

2.4 Sensor Replacement

When the instrument can no longer be spanned, as described in Section “3.0 Sen-

sor 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 - SO2

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

•O-Ring and Membrane, if required •Nonoxor II - NOX

•Monoxor II H - CO

Procedure:

WARNING!

Burn hazard! The Sensors contain corrosive chemicals,

DO NOT puncture or take the sensors apart.

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 Sen-

sor 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 ﬂat-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 short-

ing wire (across the R & S terminals) from the Sensor (SO2& CO only, the

NOXdoes 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 re-

moved 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). Con-

nect the blue (S), red (R), and black (C) wires from the P.C.B. to their as-

sociated 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.”

Single Gas Instrument Service Manual

Page 10 Bacharach, Inc. Instruction 0019-9166

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

Figure 2-4.

Sensor & Motor

Wiring Diagram

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

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

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

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

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

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-

tion.”

9. Discard the old P.C.B.

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