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Zellweger Neotronics MINIGAS MK5 Service Manual

Multiple display 4-in 1 gas monitor
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MAN0588.P65
Issue 01 - 04/00
2987M5025
MINIGAS MK5
MULTIPLE DISPLAY 4-IN 1 GAS
MONITOR

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Summary of Contents for Zellweger Neotronics MINIGAS MK5

  • Page 1 MAN0588.P65 Issue 01 - 04/00 2987M5025 MINIGAS MK5 MULTIPLE DISPLAY 4-IN 1 GAS MONITOR...
  • Page 2 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 INSTRINSIC SAFETY APPROVAL The Minigas Mk5 has been approved as intrinsically safe by authorities throughout the world. It is important that, as a matter of safety, the conditions of those approvals are maintained. The following warning was issued by BASEEFA and appeared in the EECS News (No.
  • Page 3 The Minigas Mk5 is to be serviced and the battery charged only in a safe area. Substitution of components may impair the intrinsic safety of the Minigas Mk5 - replacement parts must be approved by Zellweger Analytics. This applies to all parts, including sensors, components and accessories.
  • Page 4 ISSUE 01 - 04/00 2987M5025 WARNINGS AND CAUTIONS Zellweger Analytics Limited reserve the right to change or revise the information supplied in this document without notice and without obligation to notify any person or organisation of such revision or change.
  • Page 5 I suggest the following corrections/changes be made to Section ... Marked up copies attached (as appropriate): Yes / No Please inform me of the outcome of this change: Yes / No For Marketing Communications, Zellweger Analytics Limited: Actioned By: Date: Response: Date:...
  • Page 6 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025...

  • Page 7: Table Of Contents

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 CONTENTS section GENERAL DESCRIPTION 1.1 MINIGAS Mk5 MULTI-GAS MONITOR 1.1.1 Identification using the part number and serial number 1.2 ASSOCIATED EQUIPMENT 1.2.1 Battery charger 1.2.2 Oxygen sensor 1.2.3 Explosive-gas sensor 1.2.4 Microprocessor and associated circuits 1.2.5 TXD/RXD port 1.2.6...
  • Page 8 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 CONTENTS FAULT DIAGNOSIS 3.1 INTRODUCTION 3.2 SELF TESTS 3.2.1 Initial checks 3.2.2 Fault codes 3.2.3 Low battery fault 3.2.4 Datalogging warnings 3.3 ELECTRICAL TESTS - MINIGAS Mk5 3.3.1 Battery power supply 3.3.2 Power consumption 3.3.3 Power maintain ' circuit power and reference supplies...
  • Page 9 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 CONTENTS 4.3 SENSOR REPLACEMENT 4.3.1 Oxygen sensor 4.3.2 Toxic sensors 4.3.3 Explosive-gas sensor 4.4 CHANGES TO THE MONITORED GASES 4.4.1 Oxygen channel 4.4.2 Explosive-gas channel 4.4.3 Toxic gas channels 4.4.4 Adjusting the toxic gas null voltage 4.5 BATTERY PACKS - DISASSEMBLY AND REASSEMBLY 4.5.1...
  • Page 10 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 CONTENTS 6.2 TOOLS AND TEST EQUIPMENT 6.3 PREPARATION FOR CALIBRATION 6.3.1 General 6.3.2 Adsorption of the Test Gas 6.3.3 Purging the Gas Connections 6.4 CALIBRATION PROCEDURES 6.4.1 General 6.4.2 Entering Calibration Mode 6.4.3 Simultaneous Zeroing 6.4.4 Span Calibration 6.4.5...
  • Page 11 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6.12 TRICKLE CHARGER - STANDARD SERVICEABILITY TEST SPARES LISTS 7.1 MINIGAS Mk5 INSTRUMENT - SPARES LIST 7.2 RECHARGEABLE BATTERY PACK - SPARES LIST 7.3 DRY-CELL BATTERY PACK - SPARES LIST 7.4 FAST CHARGER - SPARES LIST 7.5 TRICKLE CHARGER - SPARES LIST GLOSSARY OF TERMS AND ABBREVIATIONS TECHNICAL BULLETINS AND SERVICE NOTES...
  • Page 12 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 FIGURES Figure Page Figure 1.1 MiniGas Mk5: functional block diagram Figure 1.2 Fast charger: functional block diagram Figure 1.3 Trickle charger: functional block diagram Figure 3.1 Missing sensor: typical oscilloscope waveforms Figure 3.2 Pellistor power circuit: typical oscilloscope waveforms Figure 3.3 ADC circuit: typical oscilloscope waveforms...

  • Page 13: General Description

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION MINIGAS MK5 MULTI-GAS MONITOR The Minigas Mk5 is a small, portable gas monitor designed to be carried or worn without hindering the user. Its purpose is to monitor the atmosphere continuously for hazardous levels of four gases simultaneously.
  • Page 14 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION Destination country (1 character) A = United States (the range of countries may be extended) C = Canada E = United Kingdom F = France G = Germany L = Spain S = Sweden X = special instrument Sensors fitted (up to 4 characters)

  • Page 15: Associated Equipment

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION The instrument serial number is shown on the label on the outside of the base casing and can also be displayed as part of the switch-on sequence (see Section 6.7.3). The serial number comprises an 8-digit code: First three digits The date of manufacture - for example,...

  • Page 16: Figure 1.1 Minigas Mk5: Functional Block Diagram

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION Note:The NIMH battery pack will switch into trickle charge when it has reached approximately 85% full charge and, therefore, requires a further 2 hours on trickle charge to reach full capacity. The NiCd battery pack, however, will not switch to trickle charge until it is 100% fully charged.

  • Page 17: Oxygen Sensor

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION On instruments not configured for monitoring a toxic gas, the analogue pcb is provided with the circuits required for carbon monoxide and hydrogen sulphide monitoring. Therefore, in the event of such a Minigas Mk5 being modified to monitor either or both of these gases, there will be no need to change the 3-pcb assembly, but a different assembly will be required if it is desired to monitor any of the other toxic gases.

  • Page 18: Microprocessor And Associated Circuits

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION 1.2.4 Microprocessor and associated circuits The microprocessor on the digital pcb is an 8-bit device running at 3.6864MHz. Normally the device is a mask-programmed ROM type 83Cl 54D, but the Minigas circuit is designed so that it can be modified to employ an EPROM type 87L58 or 87L51 FC instead.

  • Page 19: Datalogging Circuit

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION By this means it is also possible to program instrument configuration data into the EEPROM. Downloading of data is accomplished by using the LogView software package, and configuration of the instrument using the M4CONFIG program.

  • Page 20: General Description - Battery Chargers

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION • NiCd version containing four encapsulated 600mAh nickel cadmium cells, series-connected to provide a nominal 5V supply. • NIMH version containing four encapsulated 900mAh nickel metal hydride cells, series-connected to provide a nominal 5V supply.

  • Page 21: Fast Charger

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION In the dc versions, the fast charger is designed to operate only from a nominal 12V supply, but two variants of the trickle charger are available connection to either 12V or 24V (nominal) supply voltages. Transformer rectifier Battery...

  • Page 22: Trickle Charger

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION The battery temperature sensing circuit incorporates a pair of series-connected thermocouples, one in close contact with the battery pack case and the other enclosed in a sleeve over the incoming power supply cable. The change over to trickle charge occurs when the battery-to-ambient temperature difference reaches 9°C (16°F).

  • Page 23: Fuses

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION Two LEDs (both green), located on the pcb inside the unit and visible through windows in the top of the charger case, indicate the status of the charger. One is illuminated whenever power is supplied to the unit (that is, it provides a mains warning light), while the other is illuminated whenever a battery is inserted in the charger.
  • Page 24 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 1. GENERAL DESCRIPTION...

  • Page 25: Tools And Test Equipment

    2987M5025 2. TOOLS AND TEST EQUIPMENT Note:Part numbers quoted in this chapter for tools and test equipment are Zellweger part numbers. If required, these items can be purchased from Zellweger Analytics. TOOLS The following tools are required for carrying out the test and repair procedures described in this manual.

  • Page 26: Special-To-Type Test Equipment

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 2. TOOLS AND TEST EQUIPMENT 2.2.2 Special-to-type test equipment The following items of special-to-type test equipment are required for carrying out the gas tests described in this manual. • Gas calibration kit, depending on the sensors fitted (includes a gas flow regulator, a calibration hood and suitable gas tubing but excludes gas cylinders) Part no.

  • Page 27: Reconfiguration Equipment

    If available, a toxic test gas in nitrogen may be used as an alternative. In the absence of a Zellweger gas calibration kit, the following items are required for carrying out the gas tests. •...
  • Page 28 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 2. TOOLS AND TEST EQUIPMENT Electronic protection key (part no. 017-0106-02) • Universal charger unit (part no. 300-0090-00 (230V), 300-0089-00 (220V), or 300-0088-00 (110V) to provide dc power for the Data Transfer Unit.

  • Page 29: Fault Diagnosis

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS INTRODUCTION A statement of the manufacturers servicing policy with regard to the Minigas Mk5 and associated equipment is provided in Chapter 1, together with general descriptions and functional block diagrams of the monitor, battery pack and battery chargers.

  • Page 30: Initial Checks

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS 3.2.1 Initial checks Depending on the type of battery pack, when a Minigas Mk5 is returned for service either fit a fully charged NIMH or NiCd battery pack (or place the complete instrument in the fast battery charger until the green lamp lights), or fit four new dry-cell batteries.
  • Page 31 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Table 3.1 Minigas Mk5 fault codes Fault Probable reason Suggested action code for failure 100 EEPROM (25045) Reconfigure the Minigas Mk5 (M4CONFIG checksum error Version 1.05 or later). If fault persists, change the 3-pcb assembly.
  • Page 32 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Table 3.1 Minigas Mk5 fault codes Fault Probable reason Suggested action code for failure 610 Missing pellistor See Section 3.3.7. If voltages are correct, replace thermistor the pellistor. If fault persists, change the 3-pcb assembly.

  • Page 33: Fault Codes

    Minigas Mk5 (that is, monitor and battery pack) should be returned to Zellweger or an Authorised Distributor for repair, together with a note of the fault code that was displayed.

  • Page 34: Electrical Tests - Minigas Mk5

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Calibration due Only those instrument configured for datalogging have the calibration due facility because of the availability of an internal clock/calendar. Each of the four channels have their own calibration due date, which is updated automatically when that channel is recalibrated.

  • Page 35: Battery Power Supply

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Fig 3.5, 3.6 and 3.7 show outline views of the explosive-gas, digital and analogue pcb assemblies respectively. Components and terminal points referred to in this and other chapters are identified on these diagrams.

  • Page 36: Power Maintain ' Circuit Power And Reference Supplies

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS 3.3.3 Power maintain ' circuit power and reference supplies Note:The three pcb assemblies and the display module must remain connected together in the normal manner for these voltage checks. However, to avoid having to remove the existing display module from the all-in-one seal, it is permissible to connect a known serviceable module, from another instrument, to the digital pcb.

  • Page 37: Switches

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS 3.3.4 Switches Three pushbutton switches control the operation of the Minigas Mk5, viz S1 and S2 (on/select and backlight) on the analogue pcb and CALL (calibrate) on the explosive-gas pcb. In each case the effect of operating the switch is to connect a microprocessor control line (normally held at Vcc) to ground.

  • Page 38: Figure 3.1 Missing Sensor: Typical Oscilloscope Waveforms

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Under normal operating conditions, and in a fresh air environment, the output appearing across the terminals of the oxygen sensor should be within the range 16mV to 23mV. Normally, however, a Minigas Mk5 can continue to operate with a sensor output as low as 12mV - it is the drift in this output, rather than the actual value within the range, that shows when a sensor is starting to fail.

  • Page 39: Explosive-Gas Channel

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS 3.3.7 Explosive-gas channel Typical 50kHz (nominal) waveforms appearing at various points in the pellistor power circuit on the explosive-gas pcb are illustrated in Fig 3.2. In the event of the total absence of all of these waveforms, first check for the presence of the circuit power voltage (see Section 3.3.1).

  • Page 40: Figure 3.2 Pellistor Power Circuit: Typical Oscilloscope Waveforms

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS EXPLOSIVE-GAS PCB Switch-mode 50 kHz (IC3 pin 6) 0.5V and 5 s per division µ Pulse width control (IC2 pin 6) 0.5V and 5 s per division µ Monostable trigger (IC3 pin 3) 1.0V and 5 s per division µ...

  • Page 41: Adc Circuit

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Pellistor temperature compensation coefficient In order to compensate for the wide range of ambient operating temperatures of the Minigas Mk5, the pellistor requires a temperature compensation coefficient. This is incorporated in the Minigas Mk5 software and is set by the manufacturer to a value of 108.

  • Page 42: Speaker Drive

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS 3.3.9 Speaker drive The audible warning speaker is located in the sensor tray with its associated drive circuit on the digital pcb. Fig 3.4 shows a typical example of the nominal 2.5kHz audio signal produced by the push-pull driver transistors TR1 8 and TR1 9 appearing at pins 1 and 2 of the digital pcb JP5 to speaker connection.

  • Page 43: Electrical Tests - Fast Charger

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS On both versions of the battery pack, a continuity check can be carried out between B2 and B3 to test F2 + F3. Also, on rechargeable units, continuity checks can be made between B1 and B2 (F1 + F2), B1 and B3 (F1 + F3), and B1 and B6 on the fuse board (F1 only), but when doing so it is important that the positive side of the continuity tester is connected to B1.
  • Page 44 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Basically, there are two variants of the fast charger - ac (50/60Hz) and dc (motor vehicle battery). They employ similar pcb assemblies (Fig 3.10) but with the bridge rectifier (D1) omitted on the dc variant. The essential physical difference between the two variants is that the transformer (T1) is replaced in the dc version by a 1A fuse inside the top moulding.

  • Page 45: Electrical Tests - Trickle Charger

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Fig 3.10. In the case of chargers connected side-by-side in a bank and using a common ac mains supply cable, the ambient thermocouple terminals on the pcb assemblies are interconnected with twisted pairs of Type T wire as shown in Fig 3.11 ELECTRICAL TESTS - TRICKLE CHARGER WARNING Potentially lethal voltages are present on exposed terminals...

  • Page 46: Figure 3.5 Explosive-Gas Pcb Assembly

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS If the above voltages are found to be correct but the unit fails to provide the nominal 60mA trickle-charge current, then, before replacing the pcb assembly, ensure that a known serviceable battery pack is being used.

  • Page 47: Figure 3.6 Digital Pcb Assembly

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Flexible connection to Microprocessor analogue pcb R34 C10 D5 D2 D1 D8 Flexible connection to display module Contact board and lead assembly connections (battery power in and log data out) Connections to speaker Figure 3.6 Digital pcb assembly...

  • Page 48: Figure 3.7 Analogue Pcb Assembly

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Backlight switch (red button) Flexible connection to explosive-gas pcb On/Select switch Flexible connection (green button) to digital pcb Figure 3.7 Analogue pcb assembly BROWN D6 B4 62mA 62mA BLACK Batt- (ground) Batt+ (a) Rechargeable versions BROWN...

  • Page 49: Figure 3.9 Battery Pack Connectors

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS To monitor To battery charger (Rechargeable versions only) Figure 3.9 Battery pack connectors Bridge rectifier (ac variants only) Green LED BAT- Transformer soldered to pcb (ac variants only) BAT+ Red LED (a) Component side Battery thermocouple DC input...

  • Page 50: Figure 3.11 Four-Charger Bank: Interconnection Diagram

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Underside view of pcb assemblies Right-hand charger Mains in Mains out Mains in Mains out Twisted pairs of type-T wire Mains in Mains out Left-hand charger AC mains Mains in supply Heat-shrink sleeve over mains cable external to left-hand charger Figure 3.11 Four-charger bank: interconnection diagram...

  • Page 51: Figure 3.12 Trickle Charger Pcb Assembly

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS PIN 1 transformer secondary PIN 2 +12V dc input PIN 3 GREEN GREEN Ground PIN 4 BATTERY +24V dc PIN 5 input Figure 3.12 Trickle charger pcb assembly 220/240V 110V 12V to pcb 12V to pcb Figure 3.13 Trickle charger mains transformer connections...

  • Page 52: Connections - Minigas Mk5 Monitor

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS CONNECTIONS - MINIGAS MK5 MONITOR Tables 3.2 to 3.5 detail the connections between the various modules and sub-assemblies in the Minigas Mk5 monitor. Table 3.2 Explosive-gas pcb to analogue pcb connections Explosive- Description Analogue...
  • Page 53 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Table 3.3 Analogue pcb to digital pcb connections Analogue Description Digital pcb /SUPPLY PELL Circuit power Explosive signal ground Ground Battery test line 1.23V reference 200mV or 500mV reference Ground INT 1 line (CAL switch) /PWR FAIL INT 0 conversion period /MISS SENSOR...
  • Page 54 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Table 3.4 Digital pcb to display module connections Digital pcb Description Display module /ALARM 2 (red LEDs) Ground Serial bus - clock Serial bus - data out Serial bus - select display Serial bus - /busy Command/data display control /GREEN LEDs...

  • Page 55: Connections - Battery Pack And Chargers

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS CONNECTIONS - BATTERY PACK AND CHARGERS Tables 3.6 to 3.8 detail the connections between the Minigas Mk5 monitor and the battery pack, and the connections within the battery chargers. Table 3.6 Battery pack connections Battery Description Digital...
  • Page 56 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 3. FAULT DIAGNOSIS Table 3.8 Trickle charger internal connections Charger pcb Description Pins 1 & 2 Transformer secondary output, approximately 12V (ac version only) Pin 3 12V dc supply +ve Pin 4 Ground (dc supply -ve) Pin 5 24Vdc supply +ve BAT+...

  • Page 57: Maintenance

    (that is, repair) for the Minigas Mk5 monitor and its associated battery packs and battery chargers. Essentially, this consists of disassembly and reassembly instructions, sufficient to enable a Zellweger-trained technician with workshop facilities to replace those items listed as spares in Chapter 7.

  • Page 58: Sensor Grill

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE 4.2.1 Sensor grill Sensor grill M3 countersunk- head screw Goretex filter Neoprene gasket Figure 4.1 Sensor grill assembly Remove the sensor grill as follows (see Fig 4.1). Ensure that the instrument is switched off. Remove the three M3 countersunk-head screws (2mm A/F Alien key) that secure the sensor grill.

  • Page 59: Figure 4.2 Sensor Layout

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Place the sensor grill face downward and lay the gasket around its inside edge. Lay a clean Goretex filter inside the grill. Note:The Goretex filter has a 'smooth' and a 'matt' side. Ensure that the 'smooth' side is placed against the Neoprene gasket (that is, it faces outwards).

  • Page 60: Disassembly Of The Monitor Assembly (Fig 4.3)

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE 4.2.2 Disassembly of the monitor assembly (Fig 4.3) CAUTION When working with the instrument disassembled, it is recommended as good working practice to always wear a suitable anti-static protection, such as an earthed wrist strap. Take extreme care when handling the 3-pcb assembly to avoid damaging the flat-flex! connectors between the boards.
  • Page 61 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Remove the four harness-fixing screws (2mm A/F Alien key) and harness fixings. Carefully ease the base casting away from the all-in-one seal, taking care in doing so to recover the two battery retainer pushbuttons and springs.

  • Page 62: Reassembly Of The Monitor Assembly (Fig 4.3)

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE (15) Remove the two self-tapping screws that secure the speaker, sensor tray and gasket to the top casting, and then remove these items. 4.2.3 Reassembly of the monitor assembly (Fig 4.3) In general, reassembly of the monitor assembly is the reverse of the disassembly procedure.
  • Page 63 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Alternatively, having checked that the all-in-one seal fits neatly, it is possible to ease the two castings apart enough to insert the battery retainer pushbuttons and springs. Confirm that the battery retainer springs are not trapped between the castings or in the rubber sea] by checking that the pushbuttons move in and out and rotate freely.

  • Page 64: Figure 4.3 Minigas Mk5: Exploded View

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Sensor grill Toxic sensors Gasket Oxygen sensor Pellistor Filter Sensor retainer plate Battery Pack Sensor Sensor tray tray gasket casting Display module All-in-one seal 3-pcb assembly Contact board and lead assembly Pushbutton and spring Base casting...

  • Page 65: Sensor Replacement

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE SENSOR REPLACEMENT The layout of the sensors beneath the instrument grill and filter is shown in Fig 4.2. In the event of one or more sensors not being fitted, dummy sensors must be inserted in the unoccupied spaces. The fitting of dummy sensors (refer to Chapter 7 for part numbers) is important as it ensures the correct air flow over the remaining sensors.

  • Page 66: Toxic Sensors

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Refit the filter, gasket and grill (see Section 4.2.1) and allow the new sensor to settle for at least 24 hours before switching on. (10) Check and adjust the oxygen channel calibration (see Chapter 6). 4.3.2 Toxic sensors Toxic sensors are colour coded according to the gas they detect: Carbon monoxide...

  • Page 67: Explosive-Gas Sensor

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE 4.3.3 Explosive-gas sensor The procedure for replacing an explosive-gas sensor (pellistor) is as follows. Note:Because of the O-ring fitted to its body, the pellistor can be difficult to remove from the sensor tray. Switch off the Minigas Mk5 and remove the sensor grill, gasket and filter (see Section 4.2.1).

  • Page 68: Changes To The Monitored Gases

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE FLEXLINK FLEXLINK Explosive-gas pcb Analogue pcb Digital pcb R34 C10 D5 D2 D1 D8 Figure 4.4 3-pcb assembly CHANGES TO THE MONITORED GASES The following paragraphs describe the hardware modifications to a Minigas Mk5 that enable it to monitor an additional gas (partially-equipped instruments) or to monitor a different toxic gas.

  • Page 69: Oxygen Channel

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE 4.4.1 Oxygen channel The modification to a partially-equipped Minigas Mk5 to enable it to monitor oxygen consists essentially of removing the dummy sensor and fitting an oxygen sensor as described in Section 4.3.1. There is no need to completely disassemble the instrument as the connections from the sensor receptacle in the top cover assembly to the analogue pcb are made on all Minigas Mk5 variants.

  • Page 70: Adjusting The Toxic Gas Null Voltage

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE To add a toxic sensor, having checked that the correct 3-pcb assembly is fitted: In the appropriate location (Toxic 1 or Toxic 2), remove the dummy sensor and fit the new sensor as described in Section 4.3.2.

  • Page 71: Battery Packs - Disassembly And Reassembly

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Connect a battery pack to the Minigas Mk5 and switch on the instrument. Ensue that no faults or alarms are displayed during the start-up sequence. The failure to effectively short together the toxic sensor connectors will result in the display of FLt 600 (Toxic 1 channel) or Fit 605 (Toxic 2 channel).

  • Page 72: Dry-Cell Battery Pack (Fig 4.7)

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Take care to recover the two M3 nuts located in slots on the underside of the battery assembly. If it is intended to change the fuse board and case cover assembly, take note of how the leads from the battery are terminated on the board before unsoldering them (see Chapter 3 Fig 3.8).
  • Page 73 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE To the extent of the two interconnecting leads, carefully withdraw the battery holder from the front casting. Do not attempt to remove the battery cover gasket at this stage. Remove the two screws (0pt Posidriv) securing the fuse board and case cover assembly in the front casting.
  • Page 74 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Slide the fuse board and case cover assembly through the battery cover gasket and push it back into the front casting until its screw holes are visible through the holes in the side of the casting.

  • Page 75: Figure 4.5 Rechargeable Battery Pack: Exploded View

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Connector Fuse board and gasket case cover assembly O-ring Encapsulated battery assembly Battery case Sealing washer Figure 4.5 Rechargeable battery pack: exploded view O-ring Fuse board and case cover assembly Connector Battery cover gasket gasket Captive...

  • Page 76: Battery Chargers - Disassembly And Reassembly

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE BATTERY CHARGERS - DISASSEMBLY AND REASSEMBLY WARNING The battery charger must be disconnected from its power supply before any attempt is made to open the unit. Access to the interior of both types (fast and trickle) of battery charger is obtained by simply removing the base plate, which is secured to the top moulding assembly by four self-tapping screws.
  • Page 77 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Remove the four self-tapping screws that secure the base plate to the top moulding assembly. Lift off the base plate and take note of its orientation - on its inside surface there are two circular recesses that locate over the ends of the charger-connection solder pillars, and a rectangular recess that locates over the cable clamp.

  • Page 78: Figure 4.7 Fast Charger: Exploded View

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Battery spring contacts Top moulding assembly Ambient thermocouple enclosed in sleeve Power supply cable Cable clamp Transformer DC supply soldered to pcb fuse (AC versions only) Cut-out removed for interconnecting chargers in a bank DC power supply leads routed this side of pcb...
  • Page 79 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Before reassembling the fast charger, the following points should be observed: • When fitting a new transformer or new pcb assembly on ac variants, it is best to first assemble the transformer and pcb in the top moulding assembly before soldering the transformer terminals to the pcb.

  • Page 80: Trickle Charger (Fig 4.9)

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Fit the cable clamp and secure with the two self-tapping screws. Solder the battery thermocouple blue and white wires to the appropriate pcb connections. The thermocouple polarity is critical - ensure that the coloured wires are connected correctly, as shown in Chapter 3, Fig 3.10.

  • Page 81: Figure 4.8 Trickle Charger: Exploded View

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE Battery spring contacts Top moulding assembly Power supply cable DC supply fuse Power supply cable connecting direct to transformer Transformer (AC versions only) (AC versions only) Base plate Figure 4.8 Trickle charger: exploded view...
  • Page 82 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 4. MAINTENANCE...

  • Page 83: Software Options

    ISSUE 01 - 04/00 2987M5025 5. SOFTWARE OPTIONS Note:Modifying Minigas Mk5 instruments to change or add software options can be carried out only by Zellweger, an Authorised Distributor or a user who has purchased an option to use Zellweger configuration software. INTRODUCTION...

  • Page 84: Specifying A Configuration Code

    Zellweger using the procedure described in Section 5.2. SPECIFYING A CONFIGURATION CODE In order to prepare the appropriate M4CONFIG data disc, Zellweger need full details of the configuration requirements for each Minigas Mk5. For this purpose, a Minigas questionnaire (part no.

  • Page 85: Using M4Config

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 5. SOFTWARE OPTIONS Using the equipment listed in Chapter 2, Section 2.2.3, the procedure for configuring or reconfiguring a Minigas Mk5 is described in Section 5.3.2 and for decompiling a configuration code in Section 5.3.3. 5.3.2 Using M4CONFIG Ensure that the Minigas Mk5 is switched off, and then remove its battery pack.
  • Page 86 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 5. SOFTWARE OPTIONS To send the report to a file, add the file name preceded by a 'greater than' sign to the end of the definition. For example: ↵ m4decomp a03 0 ofxh > report.txt To print the report, add the printer reference preceded by a 'greater than' sign to the end of the definition.

  • Page 87: Testing And Calibration

    The Minigas Mk5 must be calibrated by authorised competent technicians using the correct equipment. If in doubt, or if the correct equipment is not available, the instrument should be returned to Zellweger Analytics or an Authorised Distributor for calibration. INTRODUCTION 6.1.1 General...
  • Page 88 Minigas Mk5. Test gases contained in cylinders fitted with a low flow gas regulator (500ml/min for chlorine, 300ml/min for all other gases). Zellweger Analytics can supply suitable calibration gases in disposable cylinders - refer to Section 8 for part numbers. Methane 1% to 1.5% VOL, or...
  • Page 89 (see Section 6.3.2). Zellweger Analytics can supply calibration kits containing the calibration hood, gas tubing and the appropriate low flow regulator - refer to Section 8 for part numbers.
  • Page 90 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION WARNING PTFE tubing MUST be used for chlorine or sulphur dioxide test gas - rubber is NOT suitable. If it is suspected that the tubing is wet, it should be dried by hanging vertically (with both ends pointing downwards) for at least 24 hours.
  • Page 91 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION CALIBRATION PROCEDURES 6.4.1 General The following procedures include instructions to apply short, medium or long duration presses on the internal calibration button. In this context, short is for a single bleep, medium is for two bleeps and long is for three bleeps.
  • Page 92 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION 6.4.3 Simultaneous Zeroing WARNING For instruments fitted with a carbon dioxide sensor, air must not be used for zeroing, as it contains an appreciable, variable concentration of CO On entering Calibration Mode the Put Air screen is displayed. This is a prompt to put the Minigas Mk5 in a clean air environment.
  • Page 93 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION 6.4.4 Span Calibration Before proceeding with span calibration, ensure that the gas connections have been purged as per the instructions given in Section 6.3.3. With the do GAS screen displayed, select Yes. While waiting for the calibration gas, or gas mixture, to be applied the upper left section of the screen alternates between Put and GAS with the expected test gas concentrations displayed in the respective...
  • Page 94 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION section of the screen with the instantaneous readings of the sensor(s) being gassed shown in their respective labelled positions. If a sensor channel is not being calibrated with the applied gas, a dash character appears in the appropriate position.
  • Page 95 If there is a calibration failure, and having ensured that there is no obvious external cause, the sensor should be replaced. Instructions for replacing any sensor will be found in the Minigas Mk5 Service Manual. Alternatively, the instrument can be returned to Zellweger or an Authorised Distributor for repair.
  • Page 96 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION 6.4.6 Storage of Calibration Results After calibration, the Minigas Mk5 stores the following data about the calibration session for downloading via LogView at a later date: Date when calibration was performed. Which channels were calibrated and whether or not they passed.
  • Page 97 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Having set all channels to the appropriate expected test gas concentration, the final press on the calibration button returns the Minigas Mk5 to the Put <> GAS screens. Continue with span calibration from operation (4) in Section 6.4.4.
  • Page 98 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION On entering Manual Calibration mode, the display shows the Select Cal Channel screen with CAL in the upper left section, the symbol of the channel selected for calibration ( -O- for oxygen, -F- for explosive, and -C- , -H- , -D- or -S- for toxic 1 or 2) in the upper right section and the current instantaneous reading in the lower right.
  • Page 99 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Apply a short press to the calibration button. The screen now displays -O- SPA and the current oxygen reading. If necessary (as in the above example), adjust the oxygen reading to be 20.9% VOL by means of the green (increase) and red (decrease) buttons.
  • Page 100 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION 6.7.3 Explosive calibration (null and span) Switch on the Minigas Mk5 and allow it to settle in clean, fresh air for at least 3 minutes. Put the instrument into Manual Calibration mode. If the screen is not displaying CAL -F- , select the explosive channel as described in Section 6.4.1.
  • Page 101 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Press the green button ('Yes') to accept the adjusted reading or the red button ('No') to reject it. In either case, the screen now displays -F- SPA and the current explosive span reading. Note:The calibrate span screen can be bypassed and the display returned to the Select Cal Channel screen by applying a further press to the calibration button.
  • Page 102 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION 6.7.4 Explosive channel temperature compensation and linearisation coefficients It may be necessary under certain circumstances to adjust the pellistor's temperature compensation coefficient (for example, if there is excessive drift of the explosive gas zero reading over the ambient temperature range) or its linearisation coefficient (if the Minigas Mk5 is required to measure accurately a high %LEL).
  • Page 103 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION The required change in the coefficient is directly proportional to the zero drift, but inversely proportional to the temperature range over which the drift occurs. For example, a zero drift of 1% LEL can be corrected by changing the existing coefficient (up or down as described above) by the following amounts: Temperature range 10°C - coefficient change 26...
  • Page 104 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Examples: A Minigas Mk5 which has been calibrated at +20°C, has a zero error of -2% LEL at +40°C. The present value of K is 108 (the actual value will be found from the Temperature Coefficient screen - refer to the procedure described below): 108 + [(-2 x 263) ÷...
  • Page 105 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Press the green button ('Yes') to accept the adjusted coefficient or the red button ('No') to reject it. In either case, the screen now displays -F- Lin and the current linearisation coefficient. If no adjustment is to be made to the linearisation coefficient (see below), apply two presses (any duration) to the calibration button to step through the Linearisation Coefficient and Second...
  • Page 106 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Apply a medium press to the calibration button to obtain the Temperature Coefficient screen (display shows -F- CCC ) and a further press (any duration) to step through to the Linearisation Coefficient screen showing -F- Lin and the current linearisation coefficient.
  • Page 107 50% LEL (2.5% VOL), the highest concentration normally available, is acceptable. Advice should be obtained from Zellweger if difficulty is found in obtaining the required test gas. Allow the Minigas Mk5 to settle in clean, fresh air for at least 3 minutes.
  • Page 108 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Switch on the Minigas Mk5 and allow it to settle in clean, fresh air for at least 3 minutes. Put the instrument into Manual Calibration mode. Select the appropriate toxic channel for calibration ( CAL -C- for carbon monoxide, CAL-L- for chlorine, CAL-d- for carbon dioxide, CAL-S- for sulphur dioxide or CAL -H- for hydrogen sulphide) by presses on the green button as described in Section 6.4.1.
  • Page 109 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Press the green button ('Yes') to accept the adjusted reading or the red button ('No') to reject it. In either case, the screen now displays -C- SPA , -L- SPA , -d-SPA , -S- SPA or -H- SPA and the current toxic span reading.
  • Page 110 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION (12) The toxic channel calibration is complete. With the Select Cal Channel screen displayed, either continue with the calibration of other toxic channel or apply a long press to the calibration button to exit calibration mode and return to the instantaneous display.
  • Page 111 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION With an oxygen calibration failure, check for contamination of the atmosphere surrounding the instrument during the calibration procedure. After calibration, a subsequent drift of the explosive gas instantaneous zero indication with ambient temperature could be because of an incorrect pellistor temperature compensation coefficient.
  • Page 112 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION If the Minigas Mk5 is a Go/NoGo instrument, first put it into calibration mode and then apply a long press to the calibration button to abort calibration mode. The instrument will then function as a conventional Minigas Mk5 providing instantaneous gas indications.
  • Page 113 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Note:As an alternative to zero grade nitrogen, a toxic test gas in nitrogen may be used for this oxygen low (deficiency) alarm test. With fully equipped instruments it is therefore permissible for this test to be done concurrently with the toxic gas tests - operations (15) to (17).
  • Page 114 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION (15) Allow the gas to flow at 300 ±50 ml/min (all gases except chlorine) or 500 ±50 ml/min (chlorine) for the time appropriate to the sensor fitted, and then ensure that the display indicates the same as the value specified on the gas cylinder within ±2ppm, and that the indication remains stable for at least 20 seconds.
  • Page 115 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION • The alarm indicators flash accompanied by a bleeping audio tone. Finally, the backlight is extinguished. • On instruments configured with the Countdown Stopwatch Alarm option, the Set dur screen, showing the timer duration that has been set, is displayed for 10 seconds at the end of the normal start-up sequence.
  • Page 116 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Switch off the Minigas Mk5 by: • pressing and holding both red and green buttons (the order of pressing the buttons is unimportant), • wait for OFF to be displayed and then release both buttons. Check the Minigas Mk5 serial number as described below in Section 6.10.3 and confirm that it agrees with the serial number on the instrument label.
  • Page 117 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Any one of the following datalogging fault warnings can be overridden and the start-up sequence restarted by applying a medium or long press to the green button. Calibration due The start-up sequence stopping with CAL duE displayed indicates that the calibration due date for one or more of the sensors has expired.

  • Page 118: Trickle Charger - Standard Serviceability Test

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 6. TESTING AND CALIBRATION Ensure that the short-circuit current is initially approximately 45mA, but after a delay of between 40 and 60 seconds it increases to approximately 370mA. Remove the milliammeter and insert a fully charged, or near fully charged, battery pack in the charger.

  • Page 119: Spares Lists

    Chapter 5. Note:The following Iists are not 'parts' Iists and should not be referred to as such. It is not Zellweger policy to include Parts Lists in their Service Manuals. When ordering spares from Zellweger, misunderstandings can best be avoided by always quoting the following information in full.

  • Page 120: Figure 7.1 Minigas Mk5 Instrument

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS Figure 7.1 Minigas Mk5 instrument...

  • Page 121: Minigas Mk5 Instrument - Spares List

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS MINIGAS MK5 INSTRUMENT - SPARES LIST Item Description Part No. Min. Qty. Top casting assembly (includes items 2987B3048 1,7,9,16,17,18,25) Base casting assembly (includes item 32): 325-9934-02 Zinc Battery retainer pushbutton 077-0264-00 Battery retainer spring 078-0032-00 Sensor grill filter:...
  • Page 122 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS Item Description Part No. Min. Qty. Display escutcheon: English label - CO and H 2987D3013 English label - CI and CO 2987D3014 English label - CI and H 2987D3015 English label - CO and SO 2987D3016 English label - H S and SO...
  • Page 123 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS Item Description Part No. Min. Qty. Toxic sensors: Carbon monoxide 138-2009-00 Hydrogen sulphide 138-2010-00 Chlorine 138-2018-00 Carbon dioxide 2050B0138 Sulphur dioxide 138-2021-00 Battery pack: NiCd rechargeable (zinc case) 325-8120-00 MiMH rechargeable (zinc case) 325-8120-02 Dry-cell (zinc case) (without cells) 325-8117-00...

  • Page 124: Rechargeable Battery Pack - Spares List

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS Figure 7.2 Rechargeable battery pack RECHARGEABLE BATTERY PACK - SPARES LIST Item Description Part No. Min. Qty. Battery case: Zinc 072-0021-00 8mm PT countersunk screw 089-9334-00 Fuse board and case cover assembly (complete with items 9 &...

  • Page 125: Figure 7.3 Dry-Cell Battery Pack

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS Figure 7.3 Dry-cell battery pack...

  • Page 126: Dry-Cell Battery Pack - Spares List

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS DRY-CELL BATTERY PACK - SPARES LIST Item Description Part No. Min. Qty. Rear cover Zinc 072-0019-02 M4 captive screw (item 11 fitted beneath the countersunk head) Battery holder 325-8110-00 M3 x 6mm countersunk screw 089-0207-06 Front casting: Zinc...

  • Page 127: Figure 7.4 Fast Charger

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS Figure 7.4 Fast charger...

  • Page 128: Fast Charger - Spares List

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS FAST CHARGER - SPARES LIST Item Description Part No. Min. Qty. Top moulding assembly (including base plate) 325-8070-00 Power supply cable assembly: 230V ac (UK) 325-8096-00 220V ac (Europe) 325-8095-00 110V ac (N America) 325-8094-00 12-16V dc 325-9567-00...

  • Page 129: Figure 7.5 Trickle Charger

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS Figure 7.5 Trickle charger...

  • Page 130: Trickle Charger - Spares List

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 7. SPARES LISTS TRICKLE CHARGER - SPARES LIST Item Description Part No. Min. Qty. Top moulding assembly (including base plate) 325-8070-00 Power supply cable assembly: 230V ac (UK) 325-9404-00 220V ac (Europe) 325-9403-00 110V ac (N America) 325-9402-00 12-16V dc 325-9567-00...

  • Page 131: Glossary Of Terms And Abbreviations

    This level of service is performed only by Zellweger. Note:Levels 1 and 2 information is provided in the Minigas Mk5 Reference Manual and level 3 in this Service Manual. Level 4 operations are not described in any Zellweger technical manual.
  • Page 132 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 8. GLOSSARY OF TERMS AND ABBREVIATIONS Calibration The process of carrying out tests, or instrument self tests, to determine whether the Minigas Mk5's performance is within specification. This is often referred 'calibration check'. Hence 'calibration adjustment' is the process of putting the instrument into Calibration Mode and making software adjustments to bring its performance...
  • Page 133 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 8. GLOSSARY OF TERMS AND ABBREVIATIONS The following abbreviations are used throughout this manual and/or appear on the Minigas Mk5 display screens: Positive Negative %LEL Percentage of lower explosive limit %VOL Percentage of the total volume Analogue-to-digital converter Across flats (spanner or wrench size) Alarm recurrence time...
  • Page 134 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 8. GLOSSARY OF TERMS AND ABBREVIATIONS NIMH Nickel metal hydride Output Oxygen Oxygen Personal computer Printed circuit board Right hand Read only memory SIRA Certification Service Sulphur dioxide STEL Short term exposure limit Time weighted average (occupational exposure limit) Toxic gas Oxygen sensor Explosive sensor (pellistor)

  • Page 135: Technical Bulletins And Service Notes

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A TECHNICAL BULLETINS AND SERVICE NOTES This Appendix includes those Neotronics Technical Bulletins still current at the time of issue of the Service Manual and applicable to the Minigas Mk5. In general, any information relevant to the servicing of the Minigas Mk5 in Technical Bulletins dated earlier than October 1997 has been incorporated in the manual.
  • Page 136 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A OPERATION OF THE MINIGAS BATTERY CHARGER Occasionally, it is reported that some Minigas battery chargers fail to change over from high to low charge-rate. Under these circumstances, the battery 'memory effect' may be increased (which is reversible) and, in extreme cases, permanent damage can be caused to the batteries.
  • Page 137 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A Replacement thermocouples and the charger-tester can be ordered from Neotronics: Part no. P300-9900-00 Charger-tester (with instructions) Part no. P300-9901-00 Kit of parts for chargers (with instructions). Once the battery charger has been repaired, any battery packs that have been used with that charger should be cycled twice, from fully discharged to fully charged.
  • Page 138 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A WHAT IS MARKING ALL ABOUT? The CE mark is put on instruments produced by Neotronics and Solomat to indicate that they comply with all applicable New Approach Directives that have been issued by the European Union. From January 1st 1996, it has become mandatory that the CE mark accompanies any of our products that are sold within the European Union.
  • Page 139 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A A Declaration of Conformity is available for each of the Neotronics products currently being sold...
  • Page 140 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A DID YOU KNOW ..an explanation of terms associated with Intrinsic Safety certification Electrical equipment that is to be used in explosive atmospheres must be certified as lntrinsically Safe. In the UK there are two organisations that can approve equipment as being Intrinsically Safe - that is, BASEEFA and SIRA.
  • Page 141 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A Symbol used to show approval to European standards for electrical equipment to be used in explosive atmospheres. CE mark, used by member countries of the European Union to show conformity with New Approach Directives that specify applicable health and safety requirements.
  • Page 142 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A Indicates that, in normal operation or with a single fault or with any combination of two faults, the electrical circuitry is not capable of igniting the specified gases. This means that the instrument can be used in areas where explosive gases are continuously present (referred to as Zone 0).
  • Page 143 MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX A CLEANING MINIGAS BATTERY CHARGING CONTACTS The charger contact studs on the Minigas NiCd and NIMH battery packs and the associated charger unit are gold-plated to ensure a good electrical contact. In some extreme conditions of use the stud surfaces can become tarnished, resulting in poor electrical contact and, hence, a greatly extended charging period.

  • Page 144: Minigas Configuration Request Form

    MAN0588.FM5 ISSUE 01 - 04/00 2987M5025 APPENDIX B MINIGAS CONFIGURATION REQUEST FORM Request form ‘MAN0560a.pdf’ for future requirements...
  • Page 145 Fax: +1 770 967 1854 Email: sieger@zelana.com Manufactured By Zellweger Analytics Ltd, Poole Dorset, UK Distributor: This publication is not intended to form the basis of a contract, and the company reserves the right to amend the design and specification of the instruments without notice.

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