ACS ALCOSIM User manual

Instruction manual

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, ALCOSIM and the “Molly” are trademarks
of Alcohol Countermeasure Systems (International) Inc. and are used under license. Alcohol
Countermeasure Systems is trading style of Alcohol Countermeasure Systems (International) Inc.
© 2012 - 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.

TABLE OF CONTENTS
Introduction.......................................................................................................... 1
Product prole ................................................................................................ 1
Product features............................................................................................. 1
Technical specications.................................................................................. 1
Limited warranty............................................................................................. 1
Assistance...................................................................................................... 2
ALCOSIM breath alcohol simulator - Overview................................................ 2
Safety and precautions....................................................................................... 3
ALCOSIM setup, usage and disassembly ..................................................... 3
Alcohol reference solution.............................................................................. 4
Cleaning the ALCOSIM breath alcohol simulator........................................... 4
Calibration materials........................................................................................... 5
Alcohol reference solution overview............................................................... 5
Alcosim setup and operation steps................................................................... 6
Troubleshooting .................................................................................................. 7
Index ..................................................................................................................... 8

ALCOSIM1
INTRODUCTION
PRODUCT PROFILE
The ALCOSIM breath alcohol simulator is used to calibrate various breath alcohol
testers. Using an embedded electronic device with a closed loop temperature
control system, the ALCOSIM simulator generates breath ow to provide a
precise calibration standard. The simulator also uses an alcohol reference
solution, the concentration of which is very sensitive. To accurately simulate
human breath, the temperature of the water-alcohol solution used in the solution
container is maintained at 34 ºC ± 0.02 ºC.
PRODUCT FEATURES
The ALCOSIM simulator is sleek and sturdy, and includes the following features:
• Microprocessor controlled, closed loop temperature system
• 7-segment Liquid Crystal Display (LCD) with a wide viewing angle
• Dual temperature sensor
• Maintains a precise temperature at 34 ºC ± 0.02 ºC
• Brushless DC motor, operating at 24VDC, capable of running 24/7
• System for detecting motor failures due to mechanical and electrical defect
• Audio and visual indication of system malfunction
TECHNICAL SPECIFICATIONS
• Height: 200mm
• Diameter: 105mm
• Weight: 1.1 kg (with power supply but w/o solution)
• Operating temperature: 23 °C ± 5 °C
• Storage temperature: 5 to 40 °C
• Storage humidity: 10 to 85% RH
• Warm-up time from cold start: < 15 minutes
• Recovery time from test: < 5 seconds
• Power supply rating: 24VDC, 2.5A, works with both 110V and 220V supplies
LIMITED WARRANTY
All ACS products are warranted to be free of defects in workmanship and
materials for a period of one year from the date of shipment. ACS agrees to
replace or repair any defective device, provided the defect was not caused by
misuse or mishandling.
Any ALCOSIM simulator being returned for warranty repairs must be properly
packaged and shipped prepaid to an authorized service provider.

INSTRUCTION MANUAL 2
ASSISTANCE
For assistance, contact your local authorized service provider or visit acs-corp.com.
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.
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

ALCOSIM3
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.
ALCOSIM SETUP, USAGE AND DISASSEMBLY
•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
•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
•Recommended: use the simulator within room temperature environments
(23 °C ± 5 °C)
•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
•Disconnect the simulator power immediately if solution overheats
considerably beyond 34 °C

INSTRUCTION MANUAL 4
•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
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

ALCOSIM5
CALIBRATION MATERIALS
•Alcohol Reference Solution, available in concentrations from 10 to 170 mg/dL.
•ALCOSIM kit (includes ALCOSIM simulator and all accessories):
•Australian kit ACS 94-001200
•UK kit ACS 94-001210
•European kit ACS 90-001220
•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
•50cm of vinyl tubing ACS 70-000002
•Liquid Trap Mouthpiece ACS 79-001955
•Round mouthpiece ACS 95-000250
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
For availability, pricing and ordering, contact your local
authorized service provider or visit acs-corp.com.

INSTRUCTION MANUAL 6
ALCOSIM SETUP AND OPERATION
STEPS
1. With the ALCOSIM breath alcohol simulator power disconnected, turn the
top housing counter clockwise (left) and detach it from the container.
2. Add the entire contents of the 500 mL bottle of 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 liquid trap 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, check
that the ALCOSIM head is tightened properly. Return the ALCOSIM to an
authorized Service Provider if the problem persists.
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 ± 0.02 ºC
Solution heat-up takes about 10 minutes. When 34 ºC ± 0.02 ºC is displayed,
the simulator is ready to provide a breath sample.
8. Use the ALCOSIM simulator to blow air into the breath alcohol tester that
you are calibrating. There are two ways of doing this:
•Manually: take a deep breath and blow for the duration of the breath test
sample period
•Mechanically: use a pump-powered air source (Recommended ow rate:
14.4 L/min)

ALCOSIM7
TROUBLESHOOTING
The following table lists error codes that may appear on the screen of the
ALCOSIM simulator. The error codes are accompanied by a periodic beep.
ERROR CODE DESCRIPTION WHAT TO DO
Er 11 Motor malfunction. Switch off the ALCOSIM simulator,
wait 5 seconds and switch it on
again.
If the error message persists, return
the simulator to an authorized
service provider.
Er 13 Transistor malfunction.
Er 21 Temperature sensor 1 has
no current.
Er 22 Temperature sensor 1 short
circuit.
Er 23 Temperature sensor 1 leak.
Er 25 Electric potential meter 1
damage.
Er 31 Temperature sensor 2 has
no current.
Er 32 Temperature sensor 2 short
circuit.
Er 33 Temperature sensor 2 leak.
Er 35 Electric potential meter 2
damage.
Er 41 Heater malfunction.
Er 52 The water level in the jar is
lower than normal.
The power supply used is
not adequate.
Fill the jar to the correct liquid volume
of 0.5L.
Use the power supply provided with the
ALCOSIM.
Er 54 Alcohol reference solution
temperature above 34 °C
for longer than 3 minutes.
The ALCOSIM simulator
attempts to restore
temperature to 34 °C. If it
cannot, the heater disables
and an Er 54 message
appears.
NOTE: Use the simulator within room
temperature environments (23 °C ±
5 °C).
Turn the simulator off in order for the
alcohol reference solution to cool down.
Turn it on again when appropriate.
Return the simulator to an authorized
service provider if the error messages
persist and ambient temperature is not
the cause.
Er 55 Alcohol reference solution
temperature above 37 °C.
The heater automatically
disables and an Er 55
message appears.