ACS ALCOLOCK V3 B-2 WI-FI Series Use and care manual

Calibration manual
SERIES B-2
ALCOLOCK V3
TM

Alcohol Countermeasure Systems Corp
60 International Boulevard
Toronto, Ontario M9W 6J2 CANADA
T [phone]
F [phone]
[email protected]
acs-corp.com
ACS, ALCOHOL COUNTERMEASURE SYSTEMS, ALCOLOCK, ALCOSIM and the “Molly” are trademarks
of Alcohol Countermeasure Systems (International) Inc. and are used under license. Alcohol Countermeasure
Systems is the trading style of Alcohol Countermeasure Systems (International) Inc.
© 2013 - 2014 Alcohol Countermeasure Systems
The information disclosed in this document is the valuable property of Alcohol Countermeasure Systems and
all copyright and other proprietary rights to this document are reserved. No reproduction of this document is
permitted without the prior written consent of Alcohol Countermeasure Systems.

Mouthpiece
Status LED
Cable input port
FRONT VIEW
SIDE VIEW
Air vent
Left navigation
button
Display
Sampling
port
*The navigation buttons
permit the selection of
options shown on the
display.
Right navigation
button

TABLE OF CONTENTS
Safety and precautions.................................................................................................1
General.....................................................................................................................1
Compressed gas safety............................................................................................1
ALCOSIM setup, usage and disassembly................................................................1
Alcohol reference solution........................................................................................2
Cleaning the ALCOSIM breath alcohol simulator.....................................................3
Calibration types ...........................................................................................................3
Handset preparation......................................................................................................3
A. With the ALCOLOCK V3 download station..........................................................3
B. By maintenance code (without the ALCOLOCK V3 download station)................4
Gas standard..................................................................................................................6
Calibration materials.................................................................................................6
Cylinder setup ..........................................................................................................6
Gas standard calibration ..........................................................................................6
Alcohol reference standard (ARS)...............................................................................8
Calibration materials.................................................................................................8
ALCOSIM breath alcohol simulator – overview........................................................9
Alcohol reference solution – overview....................................................................10
ALCOSIM setup and operation steps.....................................................................11
Alcohol reference standard (ARS) calibration ........................................................12
Troubleshooting ..........................................................................................................13
Altitude reference table...............................................................................................13

ALCOLOCK V3 SERIES B-21
SAFETY AND PRECAUTIONS
WARNING: Failure to comply with the warnings and precautions in this manual
may cause personal injury, product damage, voiding of product warranty or a
failed calibration.
GENERAL
•The ALCOSIM breath alcohol simulator is intended for authorized technicians only
•Use the ALCOSIM simulator for its intended purpose only
•Use parts specied by ACS only
•Before use, check that the simulator power supply rating (24Vdc, 2.5A) conforms to
local supply ratings
•Do not disassemble product, except as specied
•Do not attempt to repair product; you must contact an authorized service provider
•It is recommended that calibration be done indoors, in a service facility
COMPRESSED GAS SAFETY
•Damaged or broken valves can turn a canister into an unguided missile. Attach the
valve in a safe location
•Calibration should be performed indoors, in a service facility, where the gas
standard cylinder can be properly stored
•Transportation and storage of compressed gases in vehicles is dangerous and
should be avoided
•Examine the canister and valve for any damage; pay close attention to the
expiration date on the label
•Observe all cautions and safety warnings found on the canister
•Never remove or alter canister labels
•Never modify the rigid delivery tube in any way
•Always remove the valve and install the protective cap on cylinders when not in use
•Store cylinders in a cool, well ventilated area, away from sources of heat
ALCOSIM SETUP, USAGE AND DISASSEMBLY
•CAUTION! When assembling, disassembling or preparing the ALCOSIM breath
alcohol simulator for use, ensure that it is not plugged into an electrical outlet
•CAUTION! Hot surface – avoid contact with the heating element
•Place the ALCOSIM simulator on a at surface, free from obstruction
•Do not expose the simulator to direct sunlight for extended periods of time
•Do not use the simulator with any toxic or ammable liquids, or in explosive
atmospheres

CALIBRATION MANUAL 2
•Recommended: use the simulator within room temperature environments (23 °C ±
2 °C and approx. 50% RH)
•The solution container, tubing and mouthpieces must be completely dry; even slight
condensation may disrupt calibration
•Fit tubing or mouthpieces on an aquarium air pump or a similar setup for drying
•CAUTION! Never connect the simulator to an electrical outlet without rst adding
solution and attaching the top housing
•The simulator requires 500 mL of solution; the ll line is marked on the simulator
container
•Do not under or over ll the simulator container
•Do not over tighten the top housing
•Connect the simulator cables neatly to ensure simple disconnection after use
•Do not force a misaligned cable connector into place
•If solution overheats considerably beyond 34 °C, disconnect the simulator power
immediately
•Disconnect the simulator power after use
•CAUTION! After disconnecting the simulator power, allow 10 to 15 minutes for the
heating element to cool before detaching the top housing
•Empty out the solution container at the end of the work day
•Store the simulator in an environment of 5 to 40 °C and 10 to 85% RH
ALCOHOL REFERENCE SOLUTION
•Use the solution concentration specied in the manual for breath testing devices
•Replace solution every 5 days or 20 tests
•Use of solution over time affects alcohol concentration
•Do not use a solution bottle with a broken seal, or an expired bottle
•Never use articial methods to reheat or cool solution, or the solution container
•Keep solution at room temperature
•Do not freeze or refrigerate solution
•Do not ingest solution
•If solution is ingested, do not induce vomiting; contact your local poison control
centre
•Keep solution away from eyes
•If solution comes in contact with eyes, ush eyes with water; if irritation continues,
contact your local poison control centre
•Refer to your local environmental regulations for more information about safe
solution-disposal amounts
•Dispose solution down a drain

ALCOLOCK V3 SERIES B-23
CLEANING THE ALCOSIM BREATH ALCOHOL SIMULATOR
•Disconnect the ALCOSIM breath alcohol simulator power before cleaning
•CAUTION! After disconnecting the ALCOSIM simulator power, allow 10 to 15
minutes for the heating element to cool off before detaching the top housing
•Do not submerge the top housing in water
•Clean the top housing by wiping with a water dampened cloth
•Wash the solution container with plain water and dry with paper towel
CALIBRATION TYPES
There are 2 methods of calibration for the ALCOLOCK V3 alcohol interlock:
•Alcohol Reference Standard (ARS), which uses the ALCOSIM breath alcohol
simulator. See the “Alcohol Reference Standard (ARS) Calibration” section of this
manual
•Gas Standard, which uses an alcohol gas standard cylinder. See the “Gas Standard
Calibration” section of this manual
To ensure accurate results, 3 calibration cycles may be necessary. The rst cycle starts
the calibration and subsequent cycles are used to ensure that the same threshold is
met
Read the following section, then proceed to the method being used to calibrate your
handset.
HANDSET PREPARATION
Regardless of the method being used, calibration is possible both with the
ALOCOLOCK V3 Download Station or a maintenance code (without the ALCOLOCK
V3 Download Station).
Do Aor B.
A. WITH THE ALCOLOCK V3 DOWNLOAD STATION
1. Connect the ALCOLOCK V3 Download Station to a power source.
2. Disconnect the handset from the ECU of the vehicle.
Connect the handset to the ALCOLOCK V3 Download Station. The handset
powers on automatically.
3. Select CAL. The handset displays the current date and time.
4. In the Date / Time screen, do Ior II:

CALIBRATION MANUAL 4
I. If the date and time are correct, press OK – the Select method menu is
displayed.
II. If the date or time is incorrect, press Set to automatically synchronize
handset time with download station time and press OK – the Select method
menu is displayed.
NOTE: If a tachograph is installed, the date and time cannot be changed.
5. In the Select method menu, press Next to scroll to Manual and press Select. The
Select type menu is displayed.
6. Choose either Dry Gas or Wet Bath in the Select type menu. The Select value
menu is displayed.
Proceed to the “Gas Standard” section if you are using a gas standard cylinder or to
the “Alcohol Reference Standard (ARS)” section if you are using the ALCOSIM breath
alcohol simulator.
B. BY MAINTENANCE CODE (WITHOUT THE ALCOLOCK V3
DOWNLOAD STATION)
NOTE: The handset must be connected to an ECU in a vehicle or a demonstration
stand.
1. Power the handset on by holding down either the right or left navigation button.
2. Access the menu screen by pressing and holding the left button.
NOTE: Where available, press and hold the right navigation button to exit a
current screen / menu.
3. Press Next to scroll to System Maintenance and press Select.
4. Input the daily System Maintenance Code (contact an authorized dealer orACS).
To do so:
• Press [+] repeatedly to increment a digit
• Press Next to move the cursor to the next digit
5. With the code entered, press Next to move the cursor to OK and press Select.
6. In the service menu, press Next to scroll to Calibration and press Select. The
Date / Time menu is displayed.

ALCOLOCK V3 SERIES B-25
7. In the Date / Time screen, do Ior II:
I. If the date and time are correct, press OK – the Select type menu is
displayed.
II. If the date or time is incorrect, change as follows:
NOTE: If a tachograph is installed, the date and time cannot be changed.
a. Press Set to enter the Set Clock screen.
b. Press [+] repeatedly to increment a digit.
c. Press Next to move the cursor to the next digit.
NOTE: Press and hold the left button anytime to cancel time set and to return to
the Date / Time screen.
d. With the time adjusted, press Next to scroll through the options until Set is
displayed, then select Set. The Select type menu is displayed.
8. In the Select type menu, press Next to scroll between Dry Gas and Wet Bath
(depending on whether you are using a gas standard cylinder or the ALCOSIM
breath alcohol simulator) and press Select. The Select value menu is displayed.
Proceed to the “Gas Standard” section if you are using a gas standard cylinder or to
the “Alcohol Reference Standard (ARS)” section if you are using the ALCOSIM breath
alcohol simulator.

CALIBRATION MANUAL 6
GAS STANDARD
CALIBRATION MATERIALS
•105 L, 70 F cylinder of alcohol gas standard 0.24 mg/L (50 mg/dL),
ACS #95-000426
•Regulator valve assembly (6 L/min ow rate): ACS #94-000225 (trigger);
ACS #94-000226 (push button)
CYLINDER SETUP
Remove the protective cap of the canister and screw on the regulator valve assembly.
Attach the rigid delivery tube to the regulator valve. Continue to the next section.
GAS STANDARD CALIBRATION
See the “Handset Preparation” section of this manual if you are using the ALCOLOCK
V3 Download Station or a maintenance code.
1. The Select value menu contains the gas standard concentration options. Verify
your canister label, press Next to scroll to 130 PPM and press Select. This enters
the Altitude menu.
Altitude is preset to 0 (meters).
2. Determine the altitude of your exact location.
NOTE:
• Find exact altitude online
• Altitude may vary within general region or city; always use exact values
3. If your altitude is:
• 100 m or lower – leave it at 0 m. Press Accept.
• 101 m or higher – press [+] to adjust the value (increases by increments of
200 m). Round to the nearest increment (see the “Altitude Reference Table”
section of this manual). Press Accept.
Regulator valve
assembly
Rigid delivery tube
Regulator valve
Trigger release valve
Alcohol gas standard
canister

ALCOLOCK V3 SERIES B-27
4. Wait is displayed followed by a 2 minute warm-up. The handset is ready for
calibration when Turn on gas is displayed.
5. Insert the rigid delivery tube from the regulator valve into the mouthpiece port of
the handset.
Hold the handset in place for the next step.
6. Press and hold the regulator valve down to release the gas while still holding the
handset.
Blowing is displayed and the handset emits a tone.
7. Continue holding the valve down until the handset tone stops, even after the
handset clicks.
Analyzing is displayed followed by Wait and a 45 second countdown. The
handset is ready for the second sample when Turn on Gas is displayed.
Depending on the sensor calibration drift, up to 4 samples may be required.
If only 2 tests are required, VericationOK is displayed when the calibration is
complete.
If 3 or 4 tests are required, Calibration OK is displayed when the calibration is
complete.
8. Do Ior II:
I. For calibration with the ALCOLOCK V3 Download Station, disconnect
the handset from the download station and reconnect it to the ECU of the
vehicle.
II. For calibration without the ALCOLOCK V3 Download Station, press the right
button to nish (there is also the option to retry by pressing the left button).
CALIBRATION IS COMPLETE
The V3 handset returns to a ready state and Blow for 5 seconds is displayed.
NOTE: If the calibration fails on numerous attempts, the sensor may need
replacement. Contact an authorized service provider for return instructions.
Hold handset
Press valve

CALIBRATION MANUAL 8
ALCOHOL REFERENCE STANDARD (ARS)
CALIBRATION MATERIALS
•Alcohol Reference Solution, 50 mg% ACS #95-000305
•ALCOSIM kit (includes the ALCOSIM breath alcohol simulator and all accessories):
•Australian kit ACS #94-001200
•UK kit ACS #94-001210
•European kit ACS #94-001220
•North American kit ACS #94-001230
•Japanese kit ACS #94-001240
•Brazilian kit ACS #94-001250
•ALCOSIM kit contents include:
•ALCOSIM breath alcohol simulator ACS #79-007600
•AC power cord: part number depends on your region
•Power supply (24Vdc, 2.5A) ACS #07-000075
•1.5 feet of vinyl tubing ACS #70-000002
•Square mouthpiece ACS #95-000121
•Round mouthpiece ACS #95-000250

ALCOLOCK V3 SERIES B-29
ALCOSIM BREATH ALCOHOL SIMULATOR – OVERVIEW
The ALCOSIM simulator is used by technicians to calibrate and verify breath alcohol
testing devices. The simulator is a wet-bath calibration / verication device.
PARTS DIAGRAM
FRONT
Illuminated
ON/OFF
switch
Air outlet tube
Baffle plate
500 mL solution
fill line
Wide viewing angle
7-segment LCD
Temperature
sensors 1 and 2
Propeller
Stirrer
Air inlet tube
Heating
element
Dispersion
tube
BACK
Optional
thermometer port
24V power input
Communication
port
Solution
container
Top housing

CALIBRATION MANUAL 10
KIT CONNECTION DIAGRAM
ALCOHOL REFERENCE SOLUTION – OVERVIEW
The technician adds solution of precise BrAC to the ALCOSIM breath
alcohol simulator for calibration / verication of breath testing devices.
•Supplied in 500 mL tamper-sealed bottles
•Premixed and ready for immediate use with the ALCOSIM simulator
•This calibration requires a bottle of 50 mg% solution
For availability, pricing and ordering, contact your local authorized
service provider or visit acs-corp.com.
(A)
(D)
(C)
(B2)
(B1)
A Round mouthpiece (for
manually blowing into the
simulator)
B1; B2 Vinyl tubing (cut to size
by a technician)
CSquare mouthpiece
(connects to a breath
tester)
D Power cord

ALCOLOCK V3 SERIES B-211
ALCOSIM SETUP AND OPERATION STEPS
1. With the ALCOSIM breath alcohol simulator power disconnected, turn the top
housing counter clockwise (to the left) and detach it from the container.
2. Add the entire contents of the 500 mL bottle of 50 mg% alcohol reference solution
into the ALCOSIM solution container.
The bottle contains the exact liquid volume required for calibration, which is also
marked on the ALCOSIM container.
3. Return the top housing onto the container, be careful not to over tighten.
4. Connect tubing with the round mouthpiece to the ALCOSIM simulator air inlet and
tubing with the square mouthpiece to the air outlet.
5. Perform a leak check by covering the air outlet tube with your thumb and blowing
into the air inlet tube.
Air bubbles should not appear in the solution. In case of bubbling, refer to the
“Troubleshooting” section in this manual.
6. Connect the power cable to the simulator power input and to a wall outlet.
7. Switch on the simulator. The following occurs:
•The LCD display illuminates and the simulator beeps
•The propeller rotates and the heating element activates
•Cold is displayed until solution reaches 32 ºC, wherein the LCD screen
displays actual solution temperature
•The simulator maintains solution at a constant 34 ºC ± 0.2 ºC
Solution heat-up takes about 10 minutes. When 34 ºC ± 0.2 ºC is displayed, the
simulator is ready to provide a breath sample.

ALCOHOL REFERENCE STANDARD (ARS) CALIBRATION
See the “Handset Preparation” section of this manual if you are using the ALCOLOCK
V3 Download Station or a maintenance code.
1. The Select value menu contains the Alcohol Reference Standard (ARS) options.
Press Next to scroll to 50mg% and press Select. The display will count down 2
minutes and then show Ready with a solid green indicator light.
2. Insert the tip of the square mouthpiece into the sensor inlet of the handset.
3. Blow into the round mouthpiece of the ALCOSIM breath alcohol simulator.
Blowing is displayed on the handset and a continuous tone is heard. Continue
until the handset clicks.
4. The handset displays Analyzing followed by Wait and a 45 second countdown.
The handset is ready for the second sample when Ready is displayed.
Depending on the sensor calibration drift, up to 4 samples may be required.
If only 2 tests are required, VericationOK is displayed when the calibration is
complete.
If 3 or 4 tests are required, Calibration OK is displayed when calibration is
complete.
5. Do Ior II:
I. For calibration with the ALCOLOCK V3 Download Station, disconnect the
handset from the download station and reconnect it to the ECU of the vehicle.
II. For calibration without the ALCOLOCK V3 Download Station, press the right
button to nish (there is also the option to retry by pressing the left button).
CALIBRATION IS COMPLETE
The V3 handset returns to a ready state and Blow for 5 seconds is displayed.
NOTE: If the calibration fails on numerous attempts, the sensor may need to be
replaced. Contact an authorized service provider for return instructions.

TROUBLESHOOTING
In the event of a calibration failure using the ALCOSIM simulator, consult the
“Troubleshooting — Error Codes” section of the ALCOSIM Breath Alcohol Simulator
Instruction Manual (ACS #60-000180).
If a calibration fails while using an alcohol gas standard cylinder, it may be due to the
following:
•Vinyl tubing has been overused or condensation is present
•The alcohol gas standard cylinder is expired
•The alcohol gas standard value is not 130 PPM, or the value has been incorrectly
entered in the Select Value menu
•The value entered in Altitude menu is incorrect
ALTITUDE REFERENCE TABLE
The altitude adjustment is in increments of 200 meters. Round the altitude up or down
to the closest value as follows:
IF ALTITUDE IS THEN SET TO
0 - 100 m 0
101 - 300 m 200
301 - 500 m 400
501 - 700 m 600
701 - 900 m 800
901 - 1100 m 1000
1101 - 1300 m 1200
1301 - 1500 m 1400

CAM-ENG-60-000587-B
© 2013 - 2014