Alcolizer HH3 User manual

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HH3, HH4, LE5 and Centurion Sample
Module Calibration WI
Work Instruction
Di
Disclaimer –Internal Document note to reader
This document is intended for use within Alcolizer Technology only.
The contents of this document are not to be disclosed to parties outside of the
Company without permission from the appropriate Department Manager.
CHANGE STATUS
Version Number
Reason for Issue
Date
Authority
V2
Section 2.1 cleaning procedure
added. Section 8 requirements for
configuration loading upon
firmware change
April 2020
Product and
Quality
Manager
V1
Initial Release
Feb 2020
R&D and
Quality
Manager

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Contents
1Introduction .......................................................................................................................3
1.1 Risks and safety concerns ...........................................................................................3
1.2 Training requirements.................................................................................................3
Competency assessment to be completed prior to performing the tasks............................3
2Getting Started...................................................................................................................3
2.1 Cleaning Procedure .....................................................................................................4
3Device Parts .......................................................................................................................4
3.1 HH3/HH4 and LE5 Sample Module .............................................................................4
3.2 Centurion Sample Module ..........................................................................................5
3.3 HH3/HH4 and LE5 Main Module.................................................................................5
4Tools...................................................................................................................................6
5Calibration Workflow.........................................................................................................7
6Visual Inspection................................................................................................................8
7Download Logs and Update Firmware ..............................................................................8
8Configuration ...................................................................................................................10
9Pre Calibration Checks .....................................................................................................11
9.1 Initial Data Collection................................................................................................12
9.2 Device Preparation....................................................................................................12
9.3 Sample Module Leak Checks.....................................................................................13
9.4 Pump Volume Checks................................................................................................13
9.5 Backup Battery check................................................................................................13
9.6 Fuel Cell Temperature...............................................................................................13
9.7 Fuel Cell Voltage........................................................................................................14
9.8 Wet Gas Calibration ..................................................................................................14
9.9 Dry Gas Calibration....................................................................................................14
9.10 Calibration Gas.......................................................................................................15
9.11 Calibrate.................................................................................................................15
9.12 Calibration Result Display......................................................................................15
9.13 Validation Tests .....................................................................................................16
9.14 Calibration Lock Out ..............................................................................................16
10 Completing the final check List........................................................................................17
Annexure 1 - Dry Gas Conversion Table ..................................................................................18
Annexure 2 - Calibration Records Sheet.................................................................................19
Annexure 3 - Codes and Troubleshooting ...............................................................................20

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1Introduction
This Calibration Manual details the procedures for performing the calibration of the
Alcolizer alcohol breath testing device.
This manual is divided into various sections and sub-sections to enable the authorised
technician to access the required information with ease. It includes cautions and notes
applicable to calibration of Alcolizer alcohol breath testing device.
IMPORTANT NOTE
Calibration of the devices should only be performed by a qualified technical person using
certified alcohol solutions dry gas standards.
1.1 Risks and safety concerns
•Poor or inadequate lighting;
•Ergonomic hazards;
•Extremes of temperature;
•Slip, trip and fall hazards;
•Electrical hazards (e.g. appliances, power sockets, etc.);
•Fire hazards and Explosion Prevention
•Chemical hazards (e.g. cleaning products); and
•Fire and Explosion Prevention
•Manual handling
•Hazardous exposures (i.e. low humidity room, full gas bottle on the bench, fumes for
soldering, new assembly machines –don’t get in the way of an automated machine)
•RSI (i.e. crimping
•Alerts/fire alarm
•Onsite risk assessment –WHS manual
1.2 Training requirements
Competency assessment to be completed prior to performing the tasks.
2Getting Started
Prior to beginning the calibration procedure, ensure the following steps are taken and
precautions adhered too:
1. Read the entire manual carefully before calibrating the device for the first time.
2. If a dry gas standard is being used, ensure that the gas reference value has been
certified and a certification certificate is attached to the cylinder.
NOTE
Fuel cell sensors have different sensitivity parameters to wet and dry reference gas
standards, a correction factor must be applied when using dry gas as the calibration
standard to correctly correlate with wet gas solution standard.

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2.1 Cleaning Procedure
Morning start-up
•Turn gas bottles and compressed air valve on, Check you have sufficient gas before
calibrating.
•Ensure Aircon is on and the room temp is between 21-25 degrees Celsius.
•Check status of precalibration units in the service area and continue processing ie
calibrate, QC, dispatch to warehouse.
•Check recalibration tubs for units that require servicing. (Check for priority units &
ensure units dated earliest are processed first).
•Carry out calibration and repair as per work instructions.
Afternoon shut-down (15 minutes prior to end of day Monday to Thursday)
•Tidy workstation (Ensure if leaving units on bench they are in a tidy and organised
manor though it’s preferable to complete a set and clear then bench).
•Turn off gas bottles and compressed air line and purge the lines.
•Turn off computers & lights.
30 minutes prior to COB on Friday in addition to Afternoon shutdown protocol above
perform the following
•A deep clean. This includes sweeping, vacuum, wipe down benches, empty bins
make sure everything is clean and organised for Monday morning
3Device Parts
3.1 HH3/HH4 and LE5 Sample Module

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3.2 Centurion Sample Module
3.3 HH3/HH4 and LE5 Main Module
NOTE: For Centurion Main Module service refer to Centurion Main Module Service WI

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4Tools
•2mm Hex Screwdriver
•Torque Screwdriver with Phillips bit size PH1 and Hex bit number 2 (MUST be used
for pump and solenoid)
•Lint free microfiber cloth
•Henkel Loctite SF 7400 Coating –Red
•Super Lube - multipurpose synthetic-based oil with PTFE
•U-Tube manometer
•Small long nose pliers
•Scalpel
•Manual Calibration Station or Wet Gas Simulator
•Authorisation key
•Windows Computer with the latest version of AlcoCONNECT Toolbox (can be
downloaded from the web site https://www.alcolizer.com/software-updates/
Note
The torque screwdriver must be set to 30 ozf.in (21 cN.m).
Philips bit size PH1 to secure the solenoid and pump body. For the hex screws use the
Hex bit number 2.
ALWAYS CONFIRM THE SETTING BEFORE USE

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5Calibration Workflow
Visual inspection for physical damage to
the case-set or LCD, etc
Damaged:
Repair
Download logs and Update Firmware.
Charge the battery
(If Zero bars present )
Upload Configuration File
Calibrate
Internal Systems Check Fail:
Repair
Validation Testing
3 Positives, 3 Negatives
If positives within +/- 5% proceed
Battery won’t charge:
Replace the Battery
Log Calibration Data for Calibration
Certificate.
Pre Calibration Checks
If positives not within +/- 5%
Proceed to Repairs

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6Visual Inspection
•Turn the device on and check for physical damage, specifically:
oCase back and front - Replace Damaged Case-Set
oScreen - Replacing the LCD
oWrist strap if applicable
oButtons
oCharging port
oUSB port
7Download Logs and Update Firmware
•Device log records should be downloaded before any firmware updates, service or
calibration is performed.
•Connect the device to AlcoCONNECT Toolbox via the USB port.
•Enter Password 28128201 in the Set Access Field.
•Read Event Logs then save to file by date and serial number i.e.
20190416_24000745-40000987.
For example for Alcolizer staff save to A:\Service\Customer Logs
•Set the file path for Firmware location.
•File>>Options
•Firmware Upgrade Location tab
•Browse and select the firmware file
•Technician>>Check for Firmware Updates

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•Select Upload Do Not Close until Done appears
•Set device time if necessary, i.e. if the Main PCBA or backup battery has been
replaced. If the customer has made a request for change of time.
•Tools>>Set Device Time
•Sync Device to PC or Set Manually

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Note: A code error 32 is the most common error displayed after an update. Press the
power off key to turn the unit off. Then press the power key again to turn on the unit.
To avoid this error, ensure device is always switched off between firmware and
configuration uploads.
8Configuration
•Configuration files must be uploaded to the device when:
oA change to firmware has been applied to the device. This can either be an
upgrade or downgrade.
NOTE: Firmware downgrade is not a supported process and an error will occur.
Error 196/218: Could not set 1249 Configuration item not supported by device. Indicating
configuration reload is required.
oA PCBA is replaced.
•Connect the device to AlcoCONNECT via the USB port.
•Tools>>Device Config.
•Open from File.
•Select Configuration File.
•Add Serial Numbers and tick ✓Enable Upload (if the serial numbers are correct on
the device, this step is not necessary)
•Select Write to Device and Close.