Bacharach Leakator 10 User manual

LEAKATOR®10
INSTRUCTION 19-9167
COMBUSTIBLE GAS DETECTOR
Part No. 19-7051
Rev. 10 – May 2002
Bacharach, Inc.
621 Hunt Valley Circle, New Kensington, PA 15068
Ph: 724-334-5000 • Fax: [phone] • Toll Free: 800-736-4666
Website: www.bacharach-inc.com • E-mail: [email protected]
Printed in U.S.A. ® Registered Trademarks
COMBUSTIBLE GASES
G a i n

O f f
Power
Fail
Low Bat.

WARRANTY
Bacharach, Inc. warrants to Buyer that at the time of delivery
this Product will be free from defects in material and manufac-
ture and will conform substantially to Bacharach Inc.’s ap-
plicablespecifications.Bacharach’sliabilityandBuyer’sremedy
under this warranty are limited to the repair or replacement, at
Bacharach’s option, of this Product or parts thereof returned to
Seller at the factory of manufacture and shown to Bacharach
Inc.’s reasonable satisfaction to have been defective; provided
that written notice of the defect shall have been given by Buyer
toBacharachInc.withinone(1)year afterthedateofdeliveryof
this Product by Bacharach, Inc.
Bacharach, Inc. warrants to Buyer that it will convey good title
tothisProduct. Bacharach’sliabilityand Buyer’s remedy under
this warranty of title are limited to the removal of any title
defectsor,attheelectionofBacharach,tothereplacementofthis
Product or parts thereof that are defective in title.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND
ARE GIVEN AND ACCEPTED IN LIEU OF (I) ANY AND ALL
OTHERWARRANTIES,EXPRESSORIMPLIED,INCLUDING
WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE:AND (II) ANY OBLIGATION, LIABILITY, RIGHT,
CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER
OR NOT ARISING FROM BACHARACH’S NEGLIGENCE,
ACTUAL OR IMPLIED. The remedies of the Buyer shall be
limited to those provided herein to the exclusion of any and all
other remedies including, without limitation incidental or
consequentialdamages. Noagreementvaryingorextendingthe
foregoingwarranties,remedies orthislimitationwillbebinding
upon Bacharach, Inc. unless in writing, signed by a duly
authorized officer of Bacharach.
Copyright © 1994 by Bacharach, Inc.
A

Leakator 10
Instruction 19-9167 i
WARNING!
Because this instrument is used to detect and monitor materials and
conditionswhicharelistedbyOSHAorothersaspotentiallyhazardous
topersonnelandproperty,theinformationinthismanualmustbefully
understood and utilized to ensure that the instrument is operating
properly and is both used and maintained in the proper manner by
qualified personnel. An instrument that is not properly calibrated,
operated and maintained by qualified personnel is likely to provide
erroneousinformation,whichcouldpreventuserawarenessofapoten-
tiallyhazardoussituationfortheinstrumentuser,otherpersonneland
property.
If,afterreadingtheinformationinthismanual,theuserhasquestions
regardingtheoperation,applicationormaintenanceoftheinstrument,
supervisory or training assistance should be obtained before use.
Factory assistance is available by calling 724-334-5000.
Regulatory Information (Europe)
Declaration of Conformity
Manufacturer’s name: Bacharach, Inc.
Manufacturer’s address: 621 Hunt Valley Circle
New Kensington, PA 15068
European Operations: Bacharach Europe
Sovereign House, Queensway
Royal Leamington Spa
Warwickshire CV31 3JR
United Kingdom
Product name: Leakator®10
conforms to the following product
specifications:
EMC: European Directive 89/336/EEC
EN 50081-1 (Emissions)
EN 50082-1 (Immunity)

CONTENTS
Page
1.0 INTRODUCTION............................................................1
2.0 TECHNICAL CHARACTERISTICS ..............................3
3.0 BATTERY INSTALLATION ..........................................5
4.0 OPERATION ...................................................................6
4.1 Turning ON the Instrument...............................6
4.2 Taking a Gas Reading .........................................6
4.3 Using the Earphone ............................................8
4.4 Turning OFF the Instrument .............................8
5.0 MAINTENANCE.............................................................9
5.1 Replacing the Sensor...........................................9
5.2 Replacing the Printed Circuit Board .............. 12
5.3 Replacing the Speaker ..................................... 13
5.4 Replacing the Flexible Probe Assembly.......... 14
6.0 TROUBLESHOOTING ................................................ 16
7.0 PARTS/SERVICE ......................................................... 17
7.1 Parts List .......................................................... 17
7.2 Bacharach Sales/Service Centers.................... 20
Leakator 10
Instruction 19-9167ii

1.0 INTRODUCTION
The Leakator 10 is an intrinsically safe, battery-powered
portableinstrumentdesignedtoprimarilydetectthesourceof
combustible-gas leaks. The instrument is ideally suited for
heatingservicecontractors,utilitypersonnel,andotherusers
who are interested in pinpointing gas leaks, and testing gas
appliances in residential, commercial and industrial installa-
tions.
The instrument is supplied with a durable plastic carrying
case, 20" probe and instruction manual.
The Leakator 10 features:
•Ten bright-red LEDs and a speaker that provide both a
visual and audible indication to the presence of gas.
Figure 1. Leakator 10 and Accessories
1
IntroductionLeakator 10
Instruction 19-9167

•Three operation-status LEDs that show power on, sensor
operation, and low battery.
•A 20-inch flexible probe.
•Simple thumb wheel on/off and gain control allowing one-
handed operation.
•A solid-state sensor that has a typical life of 5 years.
•A battery capacity of 30 hours under normal use conditions.
•Theabilitytodetectnaturalgas(methane)inconcentrations
aslowas20ppm.Inaddition,thefollowinggasesandvapors
are also detectable:
Introduction
2
Leakator 10
Instruction 19-9167
WARNINGS!
Forsafety reasons, theLeakator 10mustonly beoperated
and serviced by qualified personnel. Read and under-
stand the contents of this instruction manual before
operating or servicing.
To prevent ignition of a hazardous atmosphere, do not
perform any maintenance work, such as replacing the
instrument’s batteries, sensor, or sensor-matching resis-
tor, in an area classified as being hazardous.
Industrial Solvents
Paint Thinners
Propane
Naphtha
Acetone
Acetylene
Ammonia
Benzene
Butane
Ethanol
Ethylene Oxide
Gasoline
Hexane
Hydrogen

2.0 TECHNICAL CHARACTERISTICS
Power..............................Five C-size Alkaline Batteries.
Battery Life ....................Approximately 30 hours of con-
tinuous operation under normal-
use conditions.
Sensor:
Type............................Solid State, plug-in replacement.
Life Expectancy ........Typically 5 years.
Calibration ................No user calibration required.
Probe...............................Self storing 20" (51 cm) flexible
probe, includes integral sensor.
Response Time...............Less than 3 seconds to full scale
indication.
Sensitivity ......................20 ppm Methane.
Warm-Up Time...............Approximately 10 seconds.
Duty Cycle ......................Continuous with no limitation.
Gas Indication................Visual: 10 red ultra-bright LEDs.
Audible: Variable speed ticking
sound (earphone provided for use
in noisy environments).
Status LEDs....................Power On (green)
Sensor Failure (yellow)
Low Battery (yellow)
Technical Characteristics
3
Leakator 10
Instruction 19-9167

Weight .............................17.8 oz (0.5 kg) (w/o batteries)
Dimensions:....................8.5" x 2.25" x 1.75"
(21.6 x 5.7 x 4.4 cm)
Operating
Environment:
Position ......................Any
Temperature .............23° to 130°F (–5° to 54°C)
Humidity....................10% to 90% RH, non-condensing
Safety Approvals............UL Classified, Intrinsically Safe
for use in Class I, Division 1,
Groups A, B, C and D. CE Mark.
Technical Characteristics
4
Leakator 10
Instruction 19-9167

3.0 BATTERY INSTALLATION
WARNING!
Do not replace batteries in a hazardous area.
CAUTION:
To maintain agency approval, use only
NEDA-14A type batteries or equivalent.
Remove battery cover. Install five (non-rechargeable) 1.5V
C-size alkaline batteries per Figure 2 – observe proper polar-
ity. Then reinstall battery cover.
Figure 2. Battery Installation
Battery Installation
5
Leakator 10
Instruction 19-9167

4.0 OPERATION
4.1 Turning ON the Instrument
Turn ON the instrument by rotating its thumb-wheel switch
(Fig 3) clockwise until a click is heard. Observe the following:
•The Power LED lights.
•The Fail LED will light, but should turn off in a few sec-
onds if the sensor is good and properly seated in its
socket.
•If the Low Bat. LED is on, replace the batteries per Sec-
tion 3.0 Battery Installation.
After the instrument stabilizes, rotate the Gain control in the
directionnecessarytocausethebottomGasLevelLEDtojust
turn off. Be sure to always set this control in the same
environment you intend to test in.
The instrument is now ready for use.
4.2 Taking a Gas Reading
To verify that the instrument is operating, sample a known
combustible gas (e.g., a gas-air mixture from an unlit burner
of a natural-gas range). If no response is observed or heard,
refer to Section 6.0 Troubleshooting.
Important! The sensor becomes less sensitive
after being exposed to an excessive amount of
gas. Therefore, after testing the instrument as
described above, leave it on for several minutes
to restabilize the sensor.
Operation
6
Leakator 10
Instruction 19-9167

Figure 3. Jack, Control, and Indicators
Operation
7
Leakator 10
Instruction 19-9167
COMBUSTIBLE GASES
Gain

Off
Power
Fail
Low Bat.
GAS
LEVEL
POWER ON
SENSOR FAILURE
LOW BATTERY
ON/OFF SWITCH &
GAIN CONTROL
20"
EARPHONE
JAC
SENSOR

Operation
Take a gas reading by positioning the end of the instrument’s
flexible probe near the area to be sampled.
The presence of a combustible gas is indicated by a column of
ten red LEDs and a speaker. The number of lighted LEDs
gives visual indication of the relative gas level, while the
speakerproducesclickingsounds,similartoaGeigercounter,
that increase in repetition rate as the gas concentration goes
up in relation to the instrument’s gain setting.
Theinstrument’ssensitivitytogasconcentrationsisadjusted
bymeansof itsthumb-wheelGaincontrol. Clockwiserotation
increases sensitivity, while counterclockwise rotation de-
creases sensitivity. The Gain control is useful in pinpointing
largeleaksbystartingwiththecontrolsettolight1or2LEDs,
and then gradually rotating the control counterclockwise as
the probe gets closer to the leak.
4.3 Using the Earphone
The earphone is an optional accessory that provides private
monitoringof theLeakator10,andis recommendedfor usein
high-noise environments. The earphone plugs into the side of
the instrument, just above the thumb-wheel control.
4.4 Turning OFF the Instrument
Turn OFF the instrument by rotating the thumb-wheel con-
trol counterclockwise until a click is heard. There is no need
to purge the instrument with fresh air before turning it off.
8
Leakator 10
Instruction 19-9167

5.0 MAINTENANCE
WARNING!
Do not replace the batteries, sensor, or sensor
matching resistor in a hazardous area.
Since the Leakator 10 does not require calibration at regular
intervals, very little needs to be done to maintain the instru-
ment in working order.
If the instrument has not been used for more than 3 months,
youmaywishtoturnitonandletitruninfreshairforseveral
minutes to keep the sensor at peak sensitivity.
If a problem should occur with your instrument, refer to
Section 6.0 Troubleshooting.
Detailed procedures of how to replace the sensor and other
components in the instrument are provided below.
5.1 Replacing the Sensor
Replacementsensorsare classifiedatthe factory accordingto
sensitivity, and are shipped with a matching resistor that
ensures the sensor will function properly when installed in
your instrument. It is important that the sensor and its
resistor be used together – DO NOT intermix resistors and
sensors.
Items required:
• Small and medium flat-blade screwdrivers
•Wire cutter
• Replacement sensor with matching resistor (P/N 19-0398)
Maintenance
9
Leakator 10
Instruction 19-9167

Procedure:
1. Turn OFF instrument.
2. Pry sensor out of its socket using a small flat-blade screw-
driver (Fig 4) and discard.
3. Remove battery cover.
4. Remove old matching resistor (Fig 5) and discard.
5. Locate new sensor’s matching resistor; then cut and bend
the resistor leads using the forms that are molded into the
battery cover (Fig 6). Note that If the resistor leads are cut
too short, the instrument may not function.
6. Insert new matching resistor into printed circuit board,
andplugnew sensorintosocket atendofprobe.Noticethat
thesensor’ssix pinsandthe socketaresymmetrical andnot
keyed,thuspermittingthesensortobepluggedintwoways.
Thesocket,however,iswiredsothatitdoesn’tmatterwhich
way the sensor is installed.
7. Install battery cover.
8. Test instrument response (refer to Section 4.2).
Figure 4. Removing Sensor
Maintenance
10
Leakator 10
Instruction 19-9167
Pry sensor from its socket
using a small flat-blade
screwdriver inserted
throu
g
h access hole.

Figure 6. Cutting and Bending Resistor Leads using Forms
Molded into Battery Cover
Maintenance
11
Leakator 10
Instruction 19-9167
Figure 5. Location of Matching Resistor
FORM
CLIP
(2 ENDS)
CAUTION: Use Only C-Size 1.5 x 5 NEDA 14A or Equivalent
Cut Matching Resistor
leads to correct length by
inserting each lead into
form as shown and cutting
here.
NOTE: The plastic clip
guide length represents the
minimum lead length. If the
resistor leads are cut too
short, the instrument may
not function.
Optimum lead length is
11/16".
After cutting resistor leads,
use this form to bend leads
as shown.
MATCHING
RESISTOR

5.2 Replacing the Printed Circuit Board
Items required:
•Medium flat-blade screwdriver
•Medium Phillips screwdriver
•Replacement printed circuit board (P/N 19-0418)
Procedure:
(See Figure 7)
1. Turn OFF instrument and lay it face down on work area.
2. Remove battery cover and batteries.
3. Remove sensor-matching resistor.
4. Remove four screws securing rear case.
5. Carefully lift rear case and flexible arm assembly away
frominstrument,beingcarefulnottopullwiresattachedto
printedcircuitboard.Layrearcasefacedownonworkarea.
6. Carefully remove printed circuit board from front case.
7. Unplug connectors J2 and J3 from printed circuit board.
8. Plug connectors J2 and J3 into new printed circuit board;
then install board into front case.
9. Install flexible arm assembly and rear case using the
screws that were removed in Step 4.
10. Replace sensor-matching resistor.
11. Replace batteries and battery cover.
12. Test instrument response (refer to Section 4.2).
Maintenance
12
Leakator 10
Instruction 19-9167

Maintenance
13
Leakator 10
Instruction 19-9167
5.3 Replacing the Speaker
Items required:
•Medium flat-blade screwdriver
•Medium Phillips screwdriver
•11/32" Nut driver
•Replacement speaker (P/N 19-0400)
Procedure:
(See Figure 7)
1. Turn OFF instrument; then remove battery cover and
batteries.
2. Remove sensor-matching resistor.
3. Remove four screws securing rear case; then carefully lift
rearcaseandflexiblearmassemblyawayfrominstrument,
being careful not to pull wires attached to printed circuit
board. Lay rear case face down on work area.
4. Carefully remove printed circuit board from front case;
thenunplugspeakerconnector J2 from printed circuit board.
5. Remove two nuts and washers securing speaker to rear
case; then remove speaker.
6. Install new speaker and secure in place using the nuts and
washers that were removed in Step 5. CAUTION! Do not
overtighten the nuts!
7. Replace flexible arm assembly and rear case using the
screws that were removed in Step 3.
8. Replace sensor-matching resistor.
9. Replace batteries and battery cover.
10. Test instrument response (refer Section 4.2).

5.4 Replacing the Flexible Probe Assembly
Items required:
•Medium flat-blade screwdriver
•Medium Phillips screwdriver
•Replacement flexible probe assembly (P/N 19-3091)
Procedure:
(See Figure 7)
1. Turn OFF instrument and lay it face down on work area.
2. Remove battery cover and batteries.
3. Remove sensor-matching resistor.
4. Remove four screws securing rear case.
5. Carefully lift rear case and flexible arm assembly away
frominstrument,beingcarefulnottopullwiresattachedto
printedcircuitboard.Layrearcasefacedownonworkarea.
6. Carefully remove printed circuit board from front case.
7. Unplug sensor connector J3 from printed circuit board.
8. Remove flexible probe assembly and remove sensor.
9. Plugconnector onnewflexibleprobeassembly intoprinted
circuit board connector J3.
Maintenance
14
Leakator 10
Instruction 19-9167

10. Replace printed circuit board, new flexible probe assem-
bly, and rear case using the screws that were removed in
Step 4.
11. Replace sensor.
12. Replace sensor-matching resistor.
13. Replace batteries and battery cover.
14. Test instrument response (refer to Section 4.2).
Maintenance
15
Leakator 10
Instruction 19-9167

Troubleshooting
6.0 TROUBLESHOOTING
WARNING!
Do not perform any maintenance work in a
hazardous area.
Because of the Leakator 10’s advanced design, trouble with
the instrument can usually be diagnosed by looking at the
LEDs as seen through the front-case. See Figure 3.
If the Fail LED lights, check that the sensor is seated and J3
is connected to the printed circuit board. If still no change,
replace the sensor per Section 5-1 Replacing the Sensor.
If the Low-Bat. LED lights, replace the batteries per Sec-
tion 3.0 as soon as possible. The instrument should operate,
however, for several hours before the batteries go dead.
If the instrument doesn’t respond to a combustible gas, per-
form the following in the order presented until the problem is
corrected:
- First ensure that all connectors are securely in place on the
printed circuit board, and that the sensor is firmly seated
into its socket.
- Replace sensor, even though the Sensor-Fail LED isn’t on,
per Section 5.1 Replacing the Sensor.
- Replace circuit board per Section 5.2 Replacing the Printed
Circuit Board.
16
Leakator 10
Instruction 19-9167