Bacharach 19-8104 Troubleshooting guide

Monoxor
®III
Carbon Monoxide Analyzer
Instruction 19-9326
Operation & Maintenance
Rev. 2 – October 2003
Product Leadership • Training • Service • Reliability

WARRANTY
Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material
and manufature and will onform substantially to Baharah In.’s aliable seiations. Baharah’s
liability and Buyer’s remedy 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 to Bacharach Inc. within two (2) years after the date of delivery of this Product by Bacharach, Inc.
Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s liability and Buyer’s
remedy under this warranty of title are limited to the removal of any title defects or, at the election of Bacharach,
to the replacement of this 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 OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IM-
PLIED 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 ARIS-
ING 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
consequential damages. No agreement varying or extending the foregoing warranties, remedies or this limita-
tion will be binding uon Baharah, In. unless in writing, signed by a duly authorized ofer of Baharah.
A
Register Your Warranty by Visiting
www.bacharach-inc.com
Notice:
Produt imrovements and enhanements are ontinuous, therefore the seiations and information on-
tained in this document may change without notice.
Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in con-
nection with the furnishing, performance, or use of this material.
No part of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of Bacharach, Inc.
Copyright © 2002–2003, Bacharach, Inc., all rights reserved.
BACHARACH and Monoxor are registered trademarks of Bacharach, Inc. All other trademarks,
trade names, service marks and logos referenced herein belong to their respective companies.
Declaration of Conformity
Manufacturer’s name: Bacharach, Inc.
Manufacturer’ 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: Monoxor III
onforms to the following seiations:
European Directive 89/336/EEC
EN50082-1: 1997 (Electrostatic Discharge)
EN50082-1: 1997 (Immunity)
EN55022; Group 1, Class B (Emission)
Instruction 19-9326

Monoxor III
Instruction 19-9326 i
Contents
1.0 INTRODUCTION ..................................................................................1
2.0 TECHNICAL CHARACTERISTICS...................................................3
3.0 PREPARING THE ANALYZER FOR OPERATION.......................5
3.1 Battery Installation .........................................................................5
3.2 Probe Installation ............................................................................6
3.3 Front Panel Pushbuttons.................................................................7
3.4 Setup Mode.......................................................................................8
3.4.1 Entering Setup ......................................................................8
3.4.2 Temperature Units Setup .....................................................8
3.4.3 CO Channel Zero Setup ........................................................9
3.4.4 Time Setup...........................................................................10
3.4.5 Date Setup ...........................................................................10
3.4.6 Year Setup ...........................................................................11
3.4.7 Selecting Printer Protocol ...................................................11
3.4.8 Exiting the Setup Screen ....................................................11
4.0 OPERATION ........................................................................................13
4.1 Taking a Gas Sample.....................................................................13
4.2 Ending a Test .................................................................................14
4.3 Turning OFF the Analyzer............................................................14
4.4 CO Purge During Turn OFF .........................................................14
4.5 CO Sensor Error Screen ................................................................15
4.6 Using the Backlight .......................................................................15
4.7 Using the Probe..............................................................................15
4.8 Operating Tips ...............................................................................16
4.9 Resetting the Microprocessor ........................................................16
4.10 Printing Test Results...................................................................17
5.0 CALIBRATION & MAINTENANCE ................................................19
5.1 Entering the Calibration Mode and Testing the Display Segments...19
5.2 Ambient Temperature Calibration ...............................................20
5.3 CO Sensor Zero & Calibration.......................................................20
5.4 Water Trap / Filter Maintenance..................................................22
5.5 CO Sensor Replacement ................................................................23
5.6 Pump Assembly Replacement .......................................................24
6.0 PARTS & SERVICE............................................................................27
6.1 Replacement Parts.........................................................................27
6.2 Accessories......................................................................................27
6.3 Service Centers ..............................................................................28
7.0 HAZARDS OF CARBON MONOXIDE.............................................29

Monoxor III
Instruction 19-9326
ii
Notes

Instruction 19-9326 1
Monoxor III
1.0 INTRODUCTION
The Monoxor III is a portable analyzer designed to detect and display
concentrations of Carbon Monoxide (CO) gas between 0 and 2000 ppm. The
analyzer is capable of testing for CO in both ambient room air, and in the
ue-gas stream of fossil-fuel red furnaces and boilers.
Ordering Information:
Part No. Description
19-8104 Monoxor III, includes 4 ‘AA’ batteries, probe & hose assembly
with integral water-trap / lter, and a hard carrying case
19-8105 Monoxor III, includes 4 ‘AA’ batteries, probe & hose assembly
with integral water-trap / lter, hard carrying case, plus
an IrDA printer with an assortment of printer accessories
including an AC adapter, roll of paper, in-car charger, belt
clip, and magnet
The analyzer detects and displays the presence of CO by rst drawing in a
gas sample from the area being tested by the analyzer’s built-in motorized
pump. The gas sample is next directed into a sensor chamber where the
sample is analyzed for the presence of CO. If CO is detected, the CO ppm
level is displayed on the analyzer’s LCD.
A permanent record of the detected CO level, along with the current time
and date, can be made by using the optional wireless IrDA printer.
A backlight enables the operator to read the display in dimly-lit areas. A
power-saver feature causes the backlight to automatically turn OFF after
10 minutes, and causes the analyzer to shut OFF after 20 minutes of inac-
tivity. The power saver feature, however, is disabled while the detected CO
level is above 50 ppm.
When the analyzer is used to measure the CO content in ue-gas, a rigid
stainless steel probe with handle is provided that allows gas samples to
be taken from within the ue stack. An integral water-trap / lter pre-
vents water and soot from being drawn into the analyzer. The probe can
also be used in ambient testing to draw in gas samples from cramped and
conned areas.
If the analyzer is turned OFF while a high level of CO is still present
within the unit, the analyzer’s pump remains running and the unit will
not turn OFF until the detected CO level drops below 50 ppm.

Instruction 19-9326
2
Monoxor III
Notes

Instruction 19-9326 3
Monoxor III
2.0 TECHNICAL CHARACTERISTICS
CO Display Range ...................... 0–2000 ppm
Accuracy ..................................... ±5% of reading or ±10 ppm,
whichever is greater*
Resolution ................................... 1 ppm
Response Time ........................... 90% of nal value within 40 sec.
Battery Requirement ................. Four disposable ‘AA’ Alkaline batteries
Operating Time .......................... Up to 18 hours continuous (pump running
and backlight off)
Warm Up Time........................... 10 or 60 seconds (depending on CO
channel zero setup, refer to Page 9)
Display ........................................ 4 digit by 2 line, 7-segment Liquid Crystal
Display
Front Panel Controls.................. Six push button switches
(refer to Section 3.3)
Operating Temperature:
Analyzer ................................. 32–104 °F (0–40 °C)
Probe....................................... 1000 °F (538 °C) max. at 5" insertion
Humidity..................................... 15 to 90% RH (non-condensing)
Printer Port ................................ IrDA or HP protocol
Weight ......................................... 16 oz with batteries
Size.............................................. 7.5"H x 3.1"W x 2.1"D (190x79x53 mm)
* Tighter accuracy in the lower ranges, up to ±2 ppm, may be attained if a
lower range calibration gas (e.g. 100 ppm CO) is used.

Instruction 19-9326
4
Monoxor III
Notes

Instruction 19-9326 5
Monoxor III
3.0 PREPARING THE ANALYZER
FOR OPERATION
To prepare a new analyzer for operation, you must install four ‘AA’
Alkaline batteries, install the probe (if needed), and set the correct time
and date as described in the following paragraphs.
For your convenience, and to ensure that the analyzer will provide reliable
CO readings, the CO sensor was installed and the analyzer calibrated on
500 ppm CO at the factory.
3.1 Battery Installation
Install fresh batteries as described below. Check the analyzer for sufcient
charge prior to each use. Replace the batteries if the low-battery symbol
appears in the lower right corner of the LCD. To install batteries:
1. Remove battery cover from back of unit (see Figure 3-1).
2. If old batteries are installed, remove and properly dispose of the
batteries.
3. Observing the polarity markings inside the battery compartment,
install four ‘AA’ Alkaline batteries.
4. Replace battery cover.
Figure 3-1. Battery Installation
          
          
               
                
           

Instruction 19-9326
6
Monoxor III
3.2 Probe Installation
Install the probe if the analyzer is going to be used for ue-gas CO mea-
surements, or if gas measurements need to be taken from a cramped or
conned area.
To install the probe, simply slide its hose over the GAS inlet of the ana-
lyzer (see Figure 3-2).
Figure 3-2. Probe Connection
      
   
         
            

Instruction 19-9326 7
Monoxor III
3.3 Front Panel Pushbuttons
Note that a push button may perform several functions, depending on what
screen is being displayed at the time.
I/O • Turns analyzer ON/OFF. There is a 10 or 60 second warm-
up and a 5 second turn-off-delay period.
•Places the analyzer into either its Setup or Calibration Mode
when used in conjunction with the ENTER or HOLD button.
• Bypasses the CO purge function during turn-off.
•Causes the displayed value to increase or change while in
the Calibration or Setup Mode.
•Causes the displayed value to decrease or change while in
the Calibration or Setup Mode.
ENTER •Starts a test – pump ON.
•Sets up the analyzer to be placed into its Calibration Mode
when held down with the analyzer OFF. (Used in conjunc-
tion with the I/O button.)
•Stores the displayed value and automatically steps to the
next screen when pressed during calibration or setup.
•Displays the CO screen when held down for 2 seconds while
in the Calibration Mode.
• Aborts turn-off and keeps the analyzer turned ON when
pressed during either the 5 second turn-off-delay period, or
the CO purge cycle.
HOLD •Freezes the display and stops the pump during a test.
•Starts a printout when pressed twice with the pump run-
ning, or when pressed once with the pump OFF.
• Sets up the analyzer to be placed into its Setup Mode when
held down with the analyzer OFF. (Used in conjunction with
the I/O button.)
LIGHT Toggles the backlight ON and OFF.

Instruction 19-9326
8
Monoxor III
3.4 Setup Mode
The analyzer is preset at the factory for the parameters shown below, but
can be changed as described in their associated sections.
Function Parameter To Change
Temperature Unit °F Section 3.4.2
CO Channel Auto Zero Section 3.4.3
Time Not Set Section 3.4.4
Date Not Set Section 3.4.5
Year Not Set Section 3.4.6
Printer IrDA Section 3.4.7
3.4.1 Entering Setup
1. With the analyzer turned OFF, press and hold down the HOLD
button.
2. Press and release the I/O button.
3. Release the HOLD button.
4. The analyzer is now in its Setup Mode. Refer to Sections 3.4.2 thru
3.4.7 for information on how to set the analyzer’s various parameters.
3.4.2 Temperature Units Setup
The Temperature Units Setup Screen is labeled “Unit”.
Note: The analyzer uses an internal temperature sensor
to maintain CO sensor accuracy under varying ambient
temperature conditions. This sensor’s temperature reading is
displayed only during calibration as described in Sec-
tion 5.2.

Instruction 19-9326 9
Monoxor III
1. Enter the Setup Mode per Section 3.4.1. If necessary, repeatedly
press ENTER until the Temperature Units Setup Screen is displayed.
2. Press the or button until the desired temperature unit
(°F or °C) is displayed.
3. Press ENTER to move to the next Setup Screen, or I/O to exit setup.
3.4.3 CO Channel Zero Setup
The CO Channel Setup Screen is labeled “CO”.
1. Enter the Setup Mode per Section 3.4.1. If necessary, repeatedly
press ENTER until the CO Channel Setup Screen is displayed.
2. Press the or button until the desired parameter is displayed.
- no Sensor disabled. Note that when the CO sensor is dis-
abled the CO measurement screen will display “Err” in-
stead of the current CO level.
- 2Ero Manual Zero – Warm-up time is 10 seconds, and the
analyzer does not zero the CO sensor to ambient conditions
during this period. For example, if the atmosphere con-
tains 25 ppm CO at start up, the analyzer will immediately
display 25 ppm. The zero point, however, can be manually
adjusted by performing Steps 1–4 of Section 5.3.
- A2 Auto Zero – Warm-up time is 60 seconds, and the CO sen-
sor is zeroed to the ambient CO level during this period. For
example, if the atmosphere contains 25 ppm CO at start up,
the analyzer will display 0 ppm. It’s very important that
when in this mode the analyzer be turned ON in fresh
air; otherwise, incorrect CO readings will occur.
3. Press ENTER to move to the next Setup Screen, or I/O to exit setup.

Instruction 19-9326
10
Monoxor III
3.4.4 Time Setup
There are two Time Setup Screens, one for hours and the other for min-
utes. Two bars appear above the segments being changed. The clock is in
a 24 hour format, but will appear as AM/PM on the printout.
�
1. Enter the Setup Mode per Section 3.4.1. If necessary, repeatedly
press ENTER until the rst Time Setup Screen is displayed—the
one with two bars over the hour digits.
2. Press the or button until the correct hour value is displayed.
3. Press ENTER to move the selection bars over the minute digits.
4. Press the or button until the correct minute value is displayed.
5. Press ENTER to move to the next Setup Screen, or I/O to exit setup.
3.4.5 Date Setup
There are two Date Setup Screens, each labeled “DAtE”. The rst screen
sets the month while the second screen sets the day.
   


1. Enter the Setup Mode per Section 3.4.1. If necessary, repeatedly
press ENTER until the rst Date Setup Screen is displayed.
2. Press the or button until the correct month is displayed.
3. Press ENTER to switch to the second Date Setup Screen.
4. Press the or key until the correct day is displayed.
5. Press ENTER to move to the next Setup Screen, or I/O to exit setup.

Instruction 19-9326 11
Monoxor III
3.4.6 Year Setup
The Year Setup Screen is labeled “yEAr”.


1. Enter the Setup Mode per Section 3.4.1. If necessary, repeatedly
press ENTER until the Year Setup Screen is displayed.
2. Press the or button until the correct year is displayed.
3. Press ENTER to move to the next Setup Screen, or I/O to exit setup.
3.4.7 Selecting Printer Protocol
The Printer Setup Screen is labeled “Prnt”. The analyzer can be set up to
send data to a wireless printer using either HP or IrDA protocol.
1. Enter the Setup Mode per Section 3.4.1. If necessary, repeatedly
press ENTER until the Printer Setup Screen is displayed.
2. Press the or button to select the desired protocol.
3. Press ENTER to move to the next Setup Screen, or I/O to exit setup.
3.4.8 Exiting the Setup Screen
Press the I/O button at any time to exit the Setup Mode and turn the ana-
lyzer OFF. Note that the last displayed parameter is automatically saved
in memory.

Instruction 19-9326
12
Monoxor III
Notes

Instruction 19-9326 13
Monoxor III
4.0 OPERATION
To operate the Monoxor III, you simply . . .
• Turn the analyzer ON
• Wait for the unit to warm up
• Take a gas sample
4.1 Taking a Gas Sample
Important! If the CO channel is set up for Auto Zero (refer
to Section 3.4.3), ensure that the analyzer will be sampling
fresh air (containing no CO) when turned ON.
Turn ON the analyzer by pressing the I/O button. Observe that when
power is rst applied, the software revision level is rst displayed followed
by a screen that counts down the warm-up period. The warm-up period is
either 60 seconds (Auto Zero Mode) or 10 seconds (Manual Zero Mode).
�
Following warm-up, the CO screen appears. This screen shows the current
detected CO level in ppm. If the probe is being used, insert the probe tip
into the area to be sampled.
    
Note: If a sensor error was detected during warm-up, the CO
Sensor Error Screen will be displayed. Refer to Section 4.5.
Front Panel Button Functions:
– No effect
– No effect
HOLD – Freezes display and stops pump; pressing a second time
activates printing
ENTER – Restarts testing after the HOLD button was pressed
LIGHT – Toggles backlight ON/OFF
I/O – Turns analyzer OFF (with a 5 second delay)

Instruction 19-9326
14
Monoxor III
4.2 Ending a Test
WARNING! Burn Hazard. Do not touch the probe after
removing it from a ue. Allow the probe to cool before han-
dling (about 5 minutes).
After taking a gas sample, remove the probe and take the analyzer to an
area containing fresh air. Allow the pump to run until the CO reading
drops to near zero.
4.3 Turning OFF the Analyzer
Turn OFF the analyzer by pressing the I/O button. The analyzer will count
down from 5 before turning OFF. Pressing ENTER, however, will abort the
count down and keep the analyzer ON.
Note: The analyzer will automatically turn itself OFF after
20 minutes of keyboard inactivity, unless the detected CO
level is above 50 ppm.
4.4 CO Purge During Turn OFF
If the detected CO level is above 50 ppm when the analyzer is turned OFF,
the unit will remain ON with its pump running and display “PUrG CO”.
The countdown from 5 will not begin until the CO level drops below
50 ppm.
Pressing ENTER during CO purge will return the analyzer to the CO
measurement screen. Although not recommended for routine use, the CO
purging process can be bypassed by pressing the I/O button a second time,
which will immediately turn OFF the analyzer.

Instruction 19-9326 15
Monoxor III
4.5 CO Sensor Error Screen
When the CO channel is set up for Auto Zero (refer to Section 3.4.3), a
CO sensor error will occur if the detected Carbon Monoxide level is above
50 ppm during the warm-up period.
Note, however, that if the CO channel is set up for manual calibration,
the analyzer does not auto-zero the CO sensor during warm-up, and thus
does not generate a CO sensor error when the analyzer is turned ON in an
atmosphere containing a high background level of CO.
Make the following checks before replacing a suspected spent or defective
sensor:
1. Turn OFF the analyzer and turn it back ON in an area of fresh air.
2. If Step 1 doesn’t eliminate the error condition, replace the sensor
per Section 5.5.
4.6 Using the Backlight
The LCD can be read in dimly-lit areas by pressing the LIGHT button.
The backlight automatically turns OFF after 10 minutes of keyboard
inactivity, but can be turned OFF at any time by again pressing the
LIGHT button.
4.7 Using the Probe
A rigid stainless steel probe with handle, connected to a exible hose with
integral water-trap / lter can be used to draw a gas sample into the ana-
lyzer from the room, grilles, diffusers, and furnace ues.
The hose and probe assembly can be detached from the analyzer when the
operator desires to sample without the probe.

Instruction 19-9326
16
Monoxor III
4.8 Operating Tips
• When an analyzer is brought in from a cold vehicle, let it warm up
slowly to minimize condensation. Temperatures below freezing will not
damage the analyzer; however, bringing a cold analyzer into a warm,
humid environment may cause condensate to form inside the case.
• If the CO channel is set up for Auto Zero (refer to Section 3.4.3), en-
sure that the analyzer is sampling fresh air when turned ON. Pulling
a ue-gas sample through the analyzer during its warm-up period will
not damage the analyzer, but it will result in incorrect CO readings.
Also note that a CO sensor error will occur if the detected CO level is
above 50 ppm during warm-up.
• Flue-gas condensate is acidic and very corrosive. It is important not to
allow the analyzer’s internal components to become soaked in conden-
sate for long periods of time.
• Before each use, inspect the lter element of the water-trap / lter as-
sembly. Replace the lter if it looks dirty.
• During a test, keep the analyzer above the water-trap, and keep the trap
in a vertical position. This will maximize the effectiveness of the trap
and keep liquid condensate from being drawn directly into the analyzer.
• When liquid condensate is seen inside the water trap, empty the trap
before it becomes full. Refer to Section 5.4.
• It is recommended that the analyzer be purged after taking a ue-gas
measurement before turning it OFF. Once the probe is removed from the
stack, disconnect the hose assembly from the bottom of the analyzer and
let the pump run for 10 minutes or so to completely remove any remain-
ing ue gases, and dry any condensate from inside the sensor chamber.
• When storing the analyzer, it’s a good idea to empty the water trap and
leave it open to further dry it out.
• Calibrate the analyzer about every 6 months to ensure its accuracy.
4.9 Resetting the Microprocessor
If the analyzer ‘locks up’ and cannot be turned OFF, reset the microproces-
sor by removing one of the batteries for 5 seconds.