Alcolizer EC Calibration Station Operating instructions

REF: EC Service and Calibration Instructions V8 Page 1 © Alcolizer Technology
EC Service and Calibration Instructions
Work Instructions
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
V4
R/O MYOB
Sep 2010
General Manager
V5
Update logo and Information
Jan 2014
General Manager
V6
Update info, new format
Sep 2016
General Manager
V7
6.1 added temperature settings
May 2017
General Manager
V8
Updated pump volume settings
and figures. Removed MYOB
filling instructions and section
5.3 Finalise Postage.
Jan 2018
Product
Manager/QMS
Manager

REF: EC Service and Calibration Instructions V8 Page 2 © Alcolizer Technology
Contents
1Prepare EC Calibration Station...........................................................................................3
2Prepare the computer program.........................................................................................3
3Remove EC from packaging from customer and restock for dispatch ..............................3
4Prepare EC for Calibration .................................................................................................3
5Calibration Process ............................................................................................................4
5.1 Firmware Upgrade ......................................................................................................7
5.2 Check Airflow ..............................................................................................................8
6Calibration Completed.....................................................................................................10
7EC Service and Calibration Checklist................................................................................10
8General Troubleshooting and Information about the EC................................................11
9Stock Codes......................................................................................................................11

REF: EC Service and Calibration Instructions V8 Page 3 © Alcolizer Technology
1Prepare EC Calibration Station
•Turn on gas at cylinder
•The gas value is determined using value on side of Ethanol bottle.
•The gas bottle setup is done by a senior technician.
2Prepare the computer program
Turn on computer and connect to EC Calibration Station found on the desktop.
3Remove EC from packaging from customer and restock for dispatch
•Check customer details on returned Calibration Request form (if form not returned
by customer complete a blank form with details to keep with paperwork).
•Get replacement Calibration Request Form (these forms are currently printed by
Print Today if stocks are running low please advise Administration Manager).
•Get replacement red/white Australia Post satchel with return AT address label.
•Fold Cal Request Form & Satchel together and neatly place into the EC Manual on
bottom of case.
•If unit is returned by customer in its hard case replace any missing mouthpieces
4Prepare EC for Calibration
•Remove EC from soft pouch
•Visually inspect unit for any damage record and damage in the notes section.
•Remove calibration sticker from back of unit. Attach to recal request form –in the
comments section.
•Unscrew battery cover.
•Unscrew main holding screw located under battery cover
•Record Fuel Cell date –on bottom of recalibration form
•Check black foam is in place on inside front cover –if not placed in correct position
(refer to assembly work instructions if necessary)
•Remove fuel cell from connection pins and check for corrosion. If no corrosion,
reposition fuel cell. If corrosion is evident, clean pins and replace fuel cell if required.
•Check that the pump volume is set between 0.11 and 0.15, 0.13 typical. Adjust and
set if required.
•Inspect pump tubing for any contamination and replace if required.
•Screw cover back together. Clean case if required.
•Replace 2 x AAA batteries.
•Perform a Current Drain test by removing one of the batteries. The unit should stay
on. If the screen fades, there is a current drain. This will require a new board.
Note
If the unit is an NRMA unit a disclaimer note should be included in the box. (Disclaimer is located at
S:\Charity\4 Forms\NRMA Disclaimer.doc). This applies to new units only.

REF: EC Service and Calibration Instructions V8 Page 4 © Alcolizer Technology
5Calibration Process
•Connect blue gas hose (Gas is set to 92 if different gas is used go into Diagnostic
mode to update details) to EC sample chamber
•Place unit in test jig located at the EC Calibration station, lock into place.
Chamber tube
Fuel cell batch#
Fuel cell connector
Foam
EC Unit
Flow meter
Cal Station
Lid and locking mechanism
Sampling tube. Connect blue hose mouthpiece
assembly to EC mouthpiece inlet port.
Pump tubing
Pump body
Pump assembly Solenoid
Make sure white solenoid
wires, are neatly tucked
away.

REF: EC Service and Calibration Instructions V8 Page 5 © Alcolizer Technology
•Turn on the computer and start the EC calibration station.
•Calibration station toolbox opens.
•Go into top right-hand corner icon with hand and paper.
•The system settings page is displayed.
•Go into Test Setup Page
•Go to drop down bar on Theme to select recalibration mode ‘Recal Sleep’
•Close the System Settings window
•Choose ‘Connect’ Icon at top left of EC Calibration Station window System will
automatically register a unit that has been in the factory historically
oCheck serial number is the same on both sticker and EC Calibration window
oIf the system does not recognize the instrument, a message will appear in a
separate window indicating “New Unit”
oWhen the system indicates “New Unit” the Edit Unit Data screen will appear
automatically.
•This information can only be updated once the testing has begun.
Click on this icon to display System
Setting setup screens required for
following operation step procedure.

REF: EC Service and Calibration Instructions V8 Page 6 © Alcolizer Technology
Caution Note:
•In the Temperature window, ensure that the ambient temperature value is set from
an accurate temperature monitor located next to the Cal Station jig assembly.
•Also, ensure that all EC units to be calibrated have been sourced from a similar
temperature environment to Cal Station jig assembly area (within ±2oC).
•If unsure of EC temperatures place EC units close to Cal Station jig assembly area and
allow at least 30 minutes for EC units to equilibrate to Cal Station area temperature
before calibrating units. Otherwise Temperature Cal errors may occur.
Note
This Edit Unit Data screen relates to information in the
old database. New devices will not have any formation
logged and therefore the boxes will be blank and not
filled out.
This edit screen can also be used to gain access to the
last calibration readings if required, should the report
not have printed out.
AT’s standard System Setup
parameters. Communication
ports and printers may vary
with different PCs.
Enter the calculated BAC value
from cylinder Ethanol PPM
value here
Enter correct ambient
temperature reading as the EC
temperature sensor will be
calibrated to this temperature
setting. The two Offset
settings should be set to 263
and 283 as shown.
Insure the correct current
firmware revision is been
used.

REF: EC Service and Calibration Instructions V8 Page 7 © Alcolizer Technology
5.1 Firmware Upgrade
Another small window will pop up asking if you wish to upgrade the firmware. This is a Yes
or No request.
•If the firmware is to be changed, please refer to firmware folder in A drive.
•Check the firmware version and that it is current
•If firmware IS NOT current, select the YES option, this will take you into the MSP430
Programmer

REF: EC Service and Calibration Instructions V8 Page 8 © Alcolizer Technology
•Go to type file enter –all files, click to highlight then open
•Hit program –you cannot do anything whilst it is programming or you may wipe out
files. Whilst firmware is upgrading EC’s screen will go blank
•Once programming complete hit close –S/N CANCELLED test complete will be
displayed on the computer
•Wait for unit to reset
•Connect –upgrade firmware No (this option will always come up)
•Once unit starts to Beep hit Next
•Check Airflow
5.2 Check Airflow
•You only need to check the airflow with the 1st EC of the day.
•Check airflow is 10L/min (this will only come up at startup of program and each time
the program is initiated)
•The screen will also show a small window at point with “Check Airflow is between 11
and 12”
•Disregard this message and check your flow meter is correctly set to 10L/min.

REF: EC Service and Calibration Instructions V8 Page 9 © Alcolizer Technology
•Choose Yes to confirm airflow.
•Unit is now under test.
•While unit is under test you can enter the required data into HW regarding this unit.
•When the system has completed testing the EC, the serial number label is printed –a
message on the bottom of the “EC Calibration Station” window will appear saying
“testing complete”.

REF: EC Service and Calibration Instructions V8 Page 10 © Alcolizer Technology
•Unit is now ready to be removed from the test jig.
•If unit failed calibration, and the reasons will be displayed why, either replace parts
that failed or put aside for service technicians to investigate.
•Before the EC is packaged back into box, wake the unit up and place the new sticker
on the back then clean the protective case before packing it back into the box.
6Calibration Completed
•When testing is complete unit will say Serial Number Passed Test complete
•Disconnect unit from test jig
•Mount battery cover, screw, recalibration sticker (the recal sticker will automatically
print from the computer on completion of recal) and box sticker if required.
•Prepare unit for postage
7EC Service and Calibration Checklist
With every EC service and calibration, a final checklist must be completed to ensure all
necessary service procedures have been completed.
Task
Completed
Replacement posting pack with calibration form has been provided
Yes / No
Missing mouth pieces have been replaced
Yes / No
Thorough visual inspection conducted and damage, if any, recorded
Yes / No
Old calibration sticker has been removed from back of unit and stuck to cal form
Yes / No
Tygon tubing checked and replaced if required
Yes / No
Fuel cell date has been recorded on bottom of calibration form
Yes / No
Black foam is in place on cover. Replace if not.
Yes / No
Fuel removed and connection pins checked for corrosion
Yes / No
Batteries have been replaced
Yes / No
Current drain test has been performed
Yes / No
Firmware has been upgraded if required
Yes / No
Unit has been calibrated
Yes / No
During calibration process, sound, air flow, LCD etc. working checks were made
Yes / No
Unit passed all checks and calibration
Yes / No
EC has been reassembled
Yes / No

REF: EC Service and Calibration Instructions V8 Page 11 © Alcolizer Technology
New calibration label with serial number has been printed and placed on EC unit
Yes / No
EC has been returned into clear protective case
Yes / No
All information has been recorded. Including what the customers has sent in, i.e.
plastic case, broken clip etc.
Yes / No
8General Troubleshooting and Information about the EC
•There is no physical way of telling if unit is a Non-Branded or NRMA to find these
details you must go to the EC Stock List and located Serial Number and details are
attached
•There is an EC QA Fault Report on system to enter details of fails i.e. Units that don’t
recal, or units that have required work.
9Stock Codes
•110010 –EC Fuel cell
•110020 –EC PCB & LCD Assembly
•120010 –EC Mouth piece nozzle (bags of 100)
•120040 –EC soft pouch
•120020 –EC plastic storage case
•120030 –EC NRMA storage case
ALL UNITS MUST BE WRAPPED IN TWO LAYERS OF BUBBLE WRAP FOR POSTAGE.