£6526 South Cottonwood Steet (300 West) . Salt Lake City, Utah 24107 © (801) 266.5300 Fax (601) 270-5590 Toll Free USA (800) 748-5355, Sales@maxtecinc.com * ynes.mastecine com ee Technical Service Manual OM-25 Series Oxygen Analyzers/Monitors R213M66A en ee_ CONTENTS| DESCRIPTION PAG SECTION 1: 1. Introduction... SECTION 2: 2. Diagnostics 2.4 L.C.D, MODULE and LED TEST 2.2 Sensor Output Window TEST. 2.3 Attach Sensor TEST. 2.4 Ato D Short Diagnostic Failure... 2.5 Ato D Over Range Diagnostic Failure 2.6 Non Active Interrupt. . 2.7 Low Battery Test... SECTION 3: 3. Troubleshooting 3.1 Block Diagram... : 3.2 Batteries and Power Distribution. 3.3 Sensor, 3.4 Main PCB... 3.5 Troubleshooting Guide: SECTION 4: 4, Rep acement Procedures 4.1 External coil replacement... 4.2 L.C.D. replacement... 4.3 Oxygen sensor replacement 4.4 Main Printed circuit board replacement. 4.5 Battery Terminal Replacement. SECTIONS: 5. Factory Adjustment Procedures SECTION 6 6. Spare and Replacement Parts. 5.1 Offset pot adjustment, |Rev.A| : ___ INTRODUCTIOI 1. INTRODUCTION NOTICE Repair of this equipment must be performed by a qualified service technician experienced in repe of portable hand held medical equipment. The OM-25 series of oxygen analyzers/monitors have been designed for maximum reliability, stable performance and low maintenance. Maxtec products/material in need of factory repair shall be sent to: Maxtec, Inc Customer Service Department 6526 South Cottonwood Street Salt Lake City, Utah 84107 (Include RMA Number) HOW TO USE THIS MANUAL This manual provides the service technician with the basic information needed to maintain and service the OM-25 series of oxygen analyzersimonitors. The manual is divided into several sections. The DIAGNOSTICS section describes self-test and service diagnostics for checking the system functions. The TROUBLESHOOTING section provides a guide to assist the service technician in locating the source of the problem. The REPLACEMENT PROCEDURES section contains instructions for removal and replacement of the assemblies that are considered field- replaceable. The FACTORY ADJUSTMENT PROCEDURES section contains the field procedures needed to restore original specifications GENERAL TROUBLESHOOTING GUIDELINES Trouble shooting the OM-25 series of oxygen analyzers should always begin by communicating with those who observed or experienced a problem with the unit. This may eliminate unnecessary trouble shooting steps. Once a general problem has been identified, refer to the troubleshooting guidelines in SECTION 3 to determine the proper corrective action to be taken. After a component has been replaced, verify that the unit is operating properly by running the appropriate diagnostic procedure. CAUTION These instruments contain electronic components that are susceptible to damage by electrostatic discharge. When disassembling the instrument, work at a static control workstation; wear a static control wrist strap to discharge accumulated static charges from you and any tool you are using. Handle the circuit boards by nonconductive edges. Use anti-static container for transporting circuit boards. [Rev. A tl2. DIAGNOSTICS DIAGNOSTICS The OM-25 series of oxygen analyzers/monitors contain a diagnostic system that monitors certain system functions and records their operational status. A series of tests are performed when the system is powered up or calibrated. The results are displayed on the L.C.D. module. The followirg paragraphs provide a description of each error code message. If no display is present upo power up, refer to SECTION 3 of this manual for trouble shooting assistance. The diagnostic tests are generic across the total line of monitors and analyzers. Where the tests may be diffarent it is noted in the text. The illustrations also use a dashed iine to indicate differences between what is viewed on the display and is accessible on the keypad by the two types of units. 2.1 LCD MODULE and LED TEST When the batteries are installed for the first time or re-installed after replacing old ones, all LCD segments end LEDSs are turned "ON" for 2 seconds. 2.2 Sensor Output Window TEST When a sersor is calibrated on air (20.9% O,) the electronics looks for an output range of 7mV to 15.82mV. When a sensor is calibrated on HI SPAN gas (approx. 109% O,) the electronics looks for an output range of 33.41mV to 75.51mvV. If the sensor falls outside of these limits the display will read "CAL", then "Er" indicating a calibration error. | Rev. A ran Monitor Note: The larger viewin module on a Monitor ove 8B 8 88 cae L Analyzer g area of the Keypad and LCD a Analyzer. ay (ASLO; _martec UEr<< C 7 DIAGNOSTIC! 2.3 Attach Sensor TEST If during operation the external sensor is disconnected from the monitor the display will blink the "ATTACH SENSOR" icon. Note: This test is only valid on a monitor version, 2.4 Ato D Short Diagnostic Failure If during operation the Analog to Digital converter see's an internal shorted input, the display will read "Ert™. 2.5 A to D Over Range Diagnostic Failure If during operation the Analog to Digital converter see's an intemal over range, the display will read "Er2". | Rev.A 2-2DIAGNOSTICS | — 2.6 Non Active Interrupt If during operation a non-active interrupt occurs the display will read "Ero", fun 2.7 Low Battery Test (( Maauao;_macec: if during operation the battery voltage | | drops below 1.8 Volts, the "LOW BAT 4 | icon will latch on and stay on until the y eo | | batteries are replaced with new ones. 1 [Rev. A : 23TROUBLE SHOOTING 3.1. OM-25 Series Block Diagram "GAG er Nax250 oF TEST POINTS CAG-25 oF KE® AND KE- cac-25088F {or Oxygen Sensor Te2(4) 10,00 15.5mVin air 1019 7P3 (GND) mar pressure = OFFSET Instcumentation Amplifier TEST POINTS Adjustment Nonrinverting Amplifier TP# (¥) output lL Vat Gains 52.4 73 (GND) 12 BRAD convertor TEST POINTS Internat 40 Veet, | Up, Pin 6 = 2.450 rat ; TP3 (GND) [_sw: ‘TEST POINTS ewe’ U2, PIN 19 (CLECt) 32.765 Khe - U2, PIN 21 oF 22 (CLK2) 4.194304 Nhe Contrast | owhite ia On nods Ory" adjustment VR 7P3 (GND) a — TEST POINTS: Tesrponts Jia" Up anmow Ee ae sins) ‘S12 LOW SET I fe. Wave (all pins — u i stent 7P3(6ND) Iioroprocessor | kevran Ba Miser ats Lock Si? ower ane it. Guo Ji cakenare Pa (GNO) TgND START LOS" — ‘By Powersupply = TEST POINTS avers [reer \res Sexo) se i [Eee | = =] P3(GND)Table 3-3~ Sensor Output Voltage Vers: “CAG 260 Seroor Ouau a Low vet Sn (Tsay pressure in ba iat 251 x (Tod os Pressure ‘Rasm Air over Various Pressurer rats) pressure in mbed01 3b) TROUBLE SHOOTING | | eawan| ouput | cup [Preven] une | ove, |reasven] Car | nim Pressurein] Output | Ouout | renee] see, | Sem (tron) | town | Hanmi | (reas) | town 1 AS ma |Fisaose) town | Hane | mole pees ee [me 62 ~(8OT aos | es ss zar | me 8a 90381450 zor | me ter ta | 8 or we me | we at | ms wooo 4.89 ote | ene tzu | oe | soot 4e wae | eam vas | cer 10021458 we tats | a sta Pog aa oes t003 18.07 we Eset | abt age t2es | ots nak os T0848 metas | az ganas |e SG sro tos 4a oe ee | aes zn | a7 880, soos 42 mo ae ee | am ams oot | oe sak | joos |e soo a | as terrace | oe | yoos 1488 wae | ae ante | moe es | so10 1468 wo bee | cer om tos | mat ssh | ran 1868 me Re | oa tsay | ae ase as | 112 4 se Mt Thar | cco oon son | ome 957 jars at me hes | om ae tao | oe as) soi 1472 as Se | et om at | masts | tors 478 mr a | oe ae | oases | sore 1475, so Me ee | we tos we | ner gh as Ye aa in se [are tos tate | ome ez | yore 1478 ee Eee | me sor waar | mae sess | yor. 140 wm thar | ome amet | ome |e raz 4at we ie | oom tam | oa a) to21 48 cmt am | om oe | ee yaos | ous 10221484 ge ee | ae oon um | mm te Me | a a6 Sots | oats | metas | 1021487 mo as7taas | at wD pos ace teas | seo 102588 1028 oo 1028 14.90+e Bl 2 2-4 3-4c Table 3-3-2: Sensor O1 uutput Voltage Verses Pressure TROUBLE SHOOTING {~ ‘©AB.250 Sensor Output at Room At over Various Pressures ow nv=10.5m x Todays prosaure n mba 13m) Hive 25m x (Todays pressure in moa/i0nbar ‘raoas| cowtat | 2824, [Peewee] ove | oxo |emsuen] ous | oma |rmanen] on tea | oupur | ema town | Honey | grist | vow ow | vigemy | means | cout | Su, osteses) | Lowry |_tign my srg Pe aes naa |e gat ag a6 oe oo 2M] aes aar | aoe cee | ew 1480 oases eas | oa | ae 88 141 om oa | ee am Powe | ee 1439 mae 2M | se aw se | oases | nee 1809 Mae we ase] amo | stn oes, tame | ge O08 16 wr «Swat | aed tags | oe arte |e usr oo Seas | set an tzos | oats nasa | an 1s0 sete seas taae | ste ons tae | et 1460 mo gw RM cs ase Too oso tago | gee 1205 aa mf aaa | eee nos tao foots ogee | fo0s 44.89 soa RR] meer ae | oo ass tses | ore O88 4s co OM aaa oee asta | aoe | 1.701465 tebe BRE Paes toas | ot asses | eT thea ns Maas | sea a00 tar | aoe ose | wor 4s wet RE | oe cor tsa | asa taee | ae an oR BB | mm oo ao | ae | tare pa ce sors 1474 wae | me soe a | ae ae | 18 tas ace BB] egos | aco taee | a 188 ur Sg ee | ee tei | oan SE 982 70884 ae RSET oor ta | gm cess | oe U8 1420 wa | ae aoe ae | aa |S 1020 tas @ ah Be | mom am | ot oso | ate 121 saa “Bot pe] ms sm | ae one | 1022 sa & i wel om sn om | os oe te | oF 1023 teas eo 2a | eo nas | oe aes | 3028 as7 me $2 Be | eae saz | aoe aes ee | 1025 sass eke as | eae az | ocean eae | 1025490 we SSR ae fas ats sas | ase ne | war t4a2 se 4s | we ges | oe oe ae | a 1028 tt03 mM st | oes oir tae | oman | 10231495 @ a 2S] we sx one | oo an one | 30 1408 we 9 fw ow aaa | oot ase |e 131 498 te RE se | oe ona | oe amo | 132 i498 eS eT | wot | sae |e 1033501 or 4 | atx | oat ata 303¢is02 pee SMbvew 1280 | amr 52s tsar | ges 'gan tt] 1035 15.04 to ME | me sas a | ost taae | tome OE 1505, en BS] mee sat | oer cata | toe 1307 em 1265, Sz eas | seg sear oon togn an OR | ener | oe aes | aoe SP 3810 7 iss | ese, wa] e50 gas tas | te0e toate an | RS] eta | oss nastae | tae I 513 oe are | MS sat nase | oe garda | toe? ss tr OB] ae ass Toss gestae | tee 8? a8 am {om sas aass | ose natu | tng OE 1617 te GR | tat sass | oes gota | toes 8S 1530 cats | se casa | ase ay | Ta 1820, so 880 are | gos ous nae | as? a wr 39.48 ts 22 fe bar aeo | ome sare: | cess wor tas tsza gt asz tet | os ae inez | ne ton t050 as 28 see RES | oe setae | oo tas teas | ay Ls ss ve | or oa one | war Rev. A 3.3[ : TROUBLE SHOOTING | 3.4. Main P.C.B, (Printed Circuit Board) Table 3-4-1 shows the bottom side of the Main PCB. High lighted in RED are the test points and important locetions. Most components on the board are non-servicsable tems except the LCD seesulo and Battery terminals. See the replacement procedures for more information on these items. Figure 3-4-1 Main PCB SB cam = 3,8 pean g e exe SHUNT Kets, Boe ozs fog. 2° LI me / oe ep me aes (j” eoend Q 2 @ | Rev. A - 3-TROUBLE SHOOTING 3.5. Troubleshooting Guides For each of the following symptoms, please reference the corresponding statements. “The LCD is blank" oe check the batteries in the unit. They may have been installed wrong or have no charge Capacity, Replace as needed. Battery charge should be greater than 1.8 VDC total. Ctsok the battery terminals. They may be bent or corroded, preventing the batteries fro making contact. Replace as needed, (See replacement procedure 4-5) Check VR2 (contrast adjustment) on Main PCB. It may have a cold solder joint of may have been twisted hard enough to break the solder traces itis connected to, Fix broken traces with a soldering iron Check board voltage test points. If they do not measure within the acceptable range, (Gee table 3-2-1) replace Main PCB, (See replacement procedure 4-4). “Batteries are going dead extremely fast” t Visually inspect battery terminals making sure that they have not been bent and are creating a dead short across the batteries «Chock board current draw. If not within the acceptable range, (See table 3-2-2) replace Main PCB, (See replacement procedure 4-4) or send back to the factory for repair “LCD has missing segments or just looks weird” «Visually inspect the display looking for cracks. This usually indicates the unit has been dropped breaking the glass. Replace the LCD module. (See replacement procedure 4-2 «Very that all pins on the LCD module are receiving a signal with an oscilloscope, Fix be traces with a soldering iron or send to the factory for repair “ Remove ered and lack wre fads | fem me aed eral oar STEP 4 | STEP Clean any solder from the holes (ut the exiting cable a shown STEP 6 Cut away the existing tis wrap and remove from the grommet, STEPT STEP 8 ull the cable through the existing | Thread the new cable through the existing grommet. (ttn water wet the ‘outer nsulaton to act asa lubricant), Loop and tighten the new te weap ‘ound the new cable es shown STEP 10 STEP 11 Apply a few drops of LocTite 444 to ‘Thread the cable through the square the tie wrap and grommet as shown. ‘opening on the back cover and solder the red wire to KEW and the black to "KE. Replace the back cover with four Philips screws followed by battenes and batlary cover,| REPLACEMENT PROCEDURES four. i - 7 [4.2L.C.0. replacement procedure, [Na ial Required: (1) R212P10 LCD modula, (4) RP92P14 Rubber bumpers, (2) R212P99 L.C.O. Absorber Pads STEP 1 (sTeP2 STEP 3 Tools Roauied Remove the battery cover and ieentity the 2 rows of 12 solder pads | Soldering iron, Solder, Solder wick, batteries from the unit. Remove the sed for soldering the LOO maduie to [our case screns trom the back of the main PCB, [ont [Seles ee seme de ‘itn the solder sucker remove al Ree athe sclera he op row Solder surounding the through ole | Din am the LCD mole tothe main 2a: Do ihe toto row rat ae STEP? [ STEP 9 1 Remove the 5 main | Remove the PCB from the enclosure Gently pry on the LCD module while | Sri tn LSD edule win eh tea pret sored tothe ers man PC vin sear ton 1 SSF wn et STEP 11 The LCD module should free itselt Apply the 4 rubper bums fram the PCB. (Note in some cases underside of the LCD module as silicon adhesive may need to be cut ‘away from the under sida of the LC | STEP 12 Place the LCD module back onto the main PCB making sure the led filer lab is located on the right side, This ide cores [Rev.A 4.2- REPLACEMENT PROCEDURES —— STEP 15 STEP 13 | STEP 14 | |r fe co mata re mn) Sr aoessory the Icuded | STEP Meet tne main PCB to the oa as shows ReS"adgute absorver pads and [fp connotes 8 | \ Femove the mylae protective flr from | | femty seated to tne matag connector ' the face of the LCD module. | fom the switen panel Replace the AA alkaline batteries while ‘vowing the LCD module. The first 2 Seconds is a LCD diagnostic mode hat tums all segments "ON", Verity all ‘segments 218 0, Roplace the main PCB with the STEP 16 | ontpe sere ontotha for ove TE MAX," eeiamance=>” [Rev.A ooREPLACEMENT PROCEDURES 4-3 Oxygen sensor relacement ly Materal Required: (1} Oxygen Sonsor (WAX-250 PIN $010002.02 or CAG-260 PIN R12SPOI-002 or CAG-25 PIN R100PSt- 002) (1) 718 crescent wrench | STEP 1 STEP 2 ‘STEPS - | Toots Required Remove Batteries, Remove the attached tube New Oxygen Sensor, 7116 crescent ‘wench, STEP 4 STEP 5 | Loosen enough to free the Oxygen | ‘sensor from the nousing STEPT, Un-package the naw sansor and if ‘required remove the Tefen tape from ‘Oxygen inlet face | step 10 STEP 11 STEP 12 Route the sensor wre ithe locations ake sue the sensor inthe mile Tighten the barb fing uni a good shown | one novsing neore tightening ihe |senliscotanee | barb iting,[step 13 [Fes in seal by tain in rosie ‘alia holes and blowing into the tube. STEP 14 Tostal he old batteries, [Rev A REPLACEMENT PROCEDURES STEP 15, ‘Sige on the sensor-battey cover and re-calibrate the new sensor per the ‘operation manual instructions, oop 4-5| REPLACEMENT PROCEDURES | 4-4 Main printed ciccuit board replacement procedure, Material Required: (1) R212P30-00X printed circuit board, Note: Pictured Aralyzer/Monitor will be different for the OM-25 A series, but the outlined procedure is the same. = —______] | STEP 1 Tools Required | | Soucoing ier, Soler, Solder wick, | | Romave the tve main PCB a ‘STEP 2 Remove the battery cover and batteries trom the urit, Remove the four case screws rom the back of the Remove the old PCB fram the enclosure grasping i wih the let hand [STEP 3 | Remove the roar case fom th font case, Remove the red ar black wes | [pa printed cect board connect the main PCB to th: Keypad connector making sure J1 is | firmly seated to the mating connector | ‘on the swith panel Replace the main PCB with the five Philips screws om t the font cover. 1 Solder tho red wire back to "KE*" and | the black wire fo KE-. Cut and re-trim the wires i hey are frayed, | remaining four Philips screws folowed 7 Replace the back cover with | Bythebanorssandbatay over. | Rev. A 4.6| 4:5 Battory Terminal Replacement | Material Requited: (4) RP13P06 Battery Terminals REPLACEMENT PROCEDURES STEP 1 | ‘STEP 2 Toots Required: | Remove the battery cover and Soldering Iron, Soler, Solder wick, | balteries from the unit. Remove the Solder sucker and Phils serew driver four case sc-ews irom the back of he STEP 3 Remove the five main PCB mounting With the solder wick or solder sucker, Take tna replacement terminal and remove the solder from the botiom align tint place torminal [ster 6 ;Make sure the termine Perpendicular tothe main PCB, and that they are perfectly parallel fo one another Re-connect the main PCB to the switch connector making sure J1 is firmly seated to the mating connector con the smitch panel STEP 10 | [seen ) [ere Rapscrtherainpce win nw ve| | Suse nebo tra age Ach ak covra te on ahostawecantetomcoe | | Sanpete bat te vomsinig fur Pip eat followed by the batteries and batteryFACTORY ADJUSTMENT PROCEDURE) 5. Factory Adjustment Procedure Equipment Required Digital Multi meter Shorting clip Small slotted screwdriver Phillips screwdriver. Rec finger nail polish 5.1, Offset pot adjustment The offset adjustment was set at the factory and should never require adjustment. In the event that the adjustment has been changed use the following procedure to correct the setting. 5.1.1 Cisconnect all sample systems to the analyzer and sensor. 5.1.2 Remove the battery cover and batteries from the unit. Remove the four case screws from the back of the unit. 5.1.3 Install batteries into the battery clips, being careful to observe correct polarity. 5.1.4 Install the shorting clip from TP2 to TP3. 54.5 With the voltmeter set for DC millivolts, attach the RED lead to TP1 and the BLACK lead to TP3. 5.1.6 Use the small slotted screwdriver and adjust VR1 up until the display on the voltmeter . reads above 40 millivolts. Then tum it back down until the reading reads 0.02 or 0.04 millivolts. Do not turn the pot below 0.01 millivolts, as the gain of the operational amplifier (U4) will be affected. 5:1.7 Paint the adjustment knob VR1 with red fingernail polish to detect tampering. Remove the shorting clip and batteries from the unit. 5.1.8 Replace the back cover with the four case screws followed by batteries and battery cover. Rev. A 5-1SPARE AND REPLACEMENT PARTS 6. Spare and Replacement Parts Part numbers for field-replaceable items on the OM-25 Series Oxygen Analyzers are listed below, along with part numbers for related hardware and cables. ITEM DESCRIPTION PART NUMBER 1 Key Pad R212P17 2 LCD Display R212P10 3 Front Cover (OM-25A, AE) R212P70-001 4 Front Cover (OM-25M, ME) R212P75-001 5 Rear Cover R212P69 6 Battery Cover R212P91 7 Barbed Fitting R212P38 8 Main PCB (OM-25A, AE) R212P30-002 9 Main PCB (OM-25M, ME) R212P30-001 40 Battery Terminals RP56PO6 11 Sensor Cable (AE, ME) Colly — R212P86 42 Sensor Cable (A, M) Internal = RP12P04-001 43 Sensor CAG-250 Internal R125P01-002 14 Sensor CAG-250E External R125P03-002 15 Sensor MAX-250 Internal $010002-02 16 Sensor MAX-250E External $010002-01 17, Sensor CAG-25 Internal R100P51-002 18 Sensor CAG-25E Extemal R110P80 149 Sensor CAG-250ESF Extemal R115P85 20 Cable Grommet RP9SPO2 21 Cable Tie RP61P01 22 Rubber Bumpers RP92P14 23 LCD Absorber Pads R212P39 24 Lens LCD Display R212P35 [RevsB. 6-1