Alcolizer WM4 User manual

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WM4 Service Work Instructions
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
V18
Updating electrical compliance and addition
of 10 minute wait for reboot cycle. Addition
of Section 8 Change of Units- Only for NON
Australian Standard compliant units.
June 2020
Quality & R&D
Manager
V17
Calibration gain limits added to section 4.8
Sample System Replacement
April 2020
Product & R&D
Manager
V16
Section 4.3.5 updated
Mar 2020
Product & Quality
Manager
V15
Firmware upgrade requirements
Feb 2020
R&D & Quality
Manager
V14
Applying and removing a short for the sample
system
Feb 2020
R&D & Quality
Manager

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Contents
1Competency Requirements ...............................................................................................4
2Risks/ Safety.......................................................................................................................4
3Equipment..........................................................................................................................4
4Service Procedure ..............................................................................................................5
4.1 Visual Inspection (Mandatory)....................................................................................5
4.1.1 Electrical Safety....................................................................................................5
4.1.2 General Defects and Wear and Tear....................................................................5
4.2 Backup Battery ............................................................................................................5
4.2.1 9 Volt Battery.......................................................................................................5
4.2.2 Rechargeable Battery Pack ..................................................................................6
4.3 Instrument Upgrade....................................................................................................6
4.3.1 Prior to Upgrade - All Instruments.......................................................................7
4.3.2 Prior to Upgrade - Releases AC-5.0 to AC12.1.....................................................7
4.3.3 Via SD Card...........................................................................................................7
4.3.4 Upgrade Coprocessor (ONLY IF UPGRADING BETWEEN AC-5 AND AC-12.1)......8
4.3.5 Upgrade SOM after the Coprocessor...................................................................9
4.3.6 Via USB.................................................................................................................9
4.3.7 Validate Migration of Settings ...........................................................................13
4.4 Gas Bottle Replacement............................................................................................14
4.5 Operation Testing (Mandatory) ................................................................................15
4.6 Leak Test....................................................................................................................15
4.6.1 Procedure...........................................................................................................16
4.7 Cleaning.....................................................................................................................19
4.8 Sample System Replacement....................................................................................20
4.9 Customise Instrument...............................................................................................21
4.9.2 Camera...............................................................................................................23
4.9.3 Camera Diagnostic .............................................................................................24
4.9.4 Coin ....................................................................................................................24
4.9.5 Coin Diagnostic ..................................................................................................24
4.9.6 Wiegand.............................................................................................................24
4.9.7 Printer ................................................................................................................28
5Rentals..............................................................................................................................29
6Packing Instruction...........................................................................................................29
7QUICK GUIDE....................................................................................................................31

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8WM4 Unit Change ( ONLY FOR NON AUSTRALIAN STANDARDS DEVICES) .....................32
8.1 Requirements............................................................................................................32
8.2 Process ......................................................................................................................32

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1Competency Requirements
•Alcolizer WM4 Service Training Program
•STP C001- Visual Test Procedure Checklist
•SWP E001- Isolation Lock-Out Tag -Out
•SWP E002- Working on Live Parts
•SWP T001- Inspection of Electrical Test Instruments
•SWP T002-Inspection of Electrical Safety Instruments
•SWP T003- Inspection & Testing of Alcolizer Units
2Risks/ Safety
•Mounting assessment
oInspect and assess that the WM4 is mounted and secured safely to the wall or
mounting position.
•Environment –Exposure to heat and sun
oEnsure access to long sleeves, hat, sunscreen, and enough water.
•Insects
oCheck for insects such as wasps and spiders that can nest in the drain tube, the
straw bin and inside the case.
•Electric Shock
oVerify portable electrical equipment is “in test” (via test tag) and free of obvious
damage before use.
oRemove plug from socket outlet before working on the Alcolizer unit (other than
for testing).
•RSI (Repetitive Strain Injury)
oCable Crimping: If pain is felt in any part of your hand or arm, stop and rest. Take
regular micro-breaks, and don’t remain in one position continually performing
the same task for extended periods of time.
•Heavy Lifting: Refrain from lifting items that you are not comfortable with.
For more information, refer to Model Codes of Practice - Hazardous Manual
Tasks (ISBN9780642333070)
•Compressed Gas
oBe aware that gas cylinders contain compressed gas at high pressure.
Although the cylinders are tested and are fit for purpose, dropping, abusing
or deliberately mishandling can cause injury.
3Equipment
•FlashPro430 JTAG Programmer
•Laptop - with FlashPro430 software installed
•SD Card with latest software or USB with latest software and blank SD Card
•Portable Appliance Tester (PAT)
•Cleaning Equipment
oSpray & Wipe
oPipe cleaners
oPaper towel

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oWater
•Shifting Spanner for regulator assembly
•8mm nut spinner for bottle clamps
•Production Level Access Key
•USB keyboard
4Service Procedure
4.1 Visual Inspection (Mandatory)
Before starting any work on an instrument, a visual inspection must be completed to
identify any possible defects or hazards. (Risk Assessment).
4.1.1 Electrical Safety
•Supply Cable- Check for any nicks, cuts or deformations of the power cable, the plug
and the cable entry on the instrument.
•240 voltage mains shield - check the shield is in place and secure.
If any of these defects are present stop work immediately, quarantine the instrument and
return instrument to base for repair. The instrument must be repaired by a qualified
technician.
4.1.2 General Defects and Wear and Tear
Visually inspect the rest of the instrument to ensure there are no other defects present:
•No foreign objects inside the instrument case
•No damage to gas bottle and regulator assembly
•No damage to any of the tubing - high pressure line, low pressure line, purge line,
drain tube, pressure sensor.
•No loose parts - gas bottle, sub-chassis, power supply, purge pump, sample system,
straw box and lid, etc.
•No damage to instrument markings - serial number, specification panel, etc. Replace
as required.
•No damage to any of the wiring.
•No damage to LCD, PCB, purge pump, sample system.
4.2 Backup Battery
The WM4 can come with either a 9-volt alkaline battery or a rechargeable battery pack.
4.2.1 9 Volt Battery
The 9-volt backup battery must be replaced to ensure that it lasts a further 12 months. The
9V battery may need to be replaced prior to the annual service as it has 50 uses of the
machine turning on and off. Should this occur, the customer can change the battery while
the machine is ON.
•New Energizer 9v alkaline batteries come with a plastic terminal cover. Remove the
terminal cover from the new battery and cover the old battery with the plastic
terminal cover prior to disposing into the battery bin.
•Replace with the new 9volt alkaline battery.

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4.2.2 Rechargeable Battery Pack
The rechargeable battery pack does not need to be changed at every service as the WM will
continue to keep it charged. If the WM has frequent power losses or is frequently turned
off, the rechargeable battery pack will drain. If the wall mount has an error message on the
screen referring to the battery backup low, the following process is required:
•The backup battery needs to be disconnected from the PCBA and connected to the
battery charger. The charging process can take up to an hour.
•When fully charged, the light on the charger will remain steady and green.
•The charger can be removed and the battery pack can be plugged back into the
PCBA.
4.3 Instrument Upgrade
Use SD and FlashPro when upgrading instruments prior to AC-13.
Use USB when upgrading instruments AC-13 and above.

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Figure 1- Status LED
Please note: Programming Reboot cycle may take up to 10 minutes to take
effect the unit may appear frozen in this time.
4.3.1 Prior to Upgrade - All Instruments
At no point in the procedure should the backup battery be removed. The backup battery
should be replaced before starting the instrument upgrade or at the end.
4.3.2 Prior to Upgrade - Releases AC-5.0 to AC12.1
•Ensure Field Technician Authorisation key is inserted
•Navigate to the Settings page and select Shutdown Instrument (bottom right corner
using the spacebar then arrow up to upgrade and use spacebar to select)
•Select Upgrade
•Four black circles indicate settings have been exported successfully
VERY IMPORTANT: When the database exports, as the instrument shuts down it will show
four circles that will change from white to black as the process completes. If the process
does not show four filled in black circles OR at any point shows red circles, then the
database export has failed and should be restarted. If the export fails repeatedly the issue
needs to be escalated to your manager prior to any upgrade of the instrument software.
DO NOT remove the backup battery. Removing the backup battery will cause the
instrument clock to reset forcing a ten-minute wait on calibration when the clock is
synchronised.
•Wait for the STAT5 LED to be solid green. STAT1 to STAT4 should all be off.
•Remove mains power
oAll LED’s should turn off. STAT1 to STAT5 should all be off.
4.3.3 Via SD Card
During these steps some buttons on the back of the device are pressed and held over
multiple steps. It is important to not release buttons until the instructions indicate to do so.
Make sure to read and comprehend all instructions before starting the upgrade process.
The upgrade instructions refer to LEDs and
buttons on the back of the instrument as
pictured. It is important to be familiar with
the buttons and LEDs before undertaking
the instrument upgrade procedure.

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Figure 2- FlashPro430 Settings
Figure 3- FlashPro430 Programmer
4.3.4 Upgrade Coprocessor (ONLY IF UPGRADING BETWEEN AC-5 AND AC-12.1)
Ensure instrument is off and mains power is removed as per the previous sections.
•Before continuing ensure that:
□All SD cards are removed
□The battery remains inserted.
•Start the FlashPro430 software.
•Select the u_main.hex file for the SD Card with the latest software.
•Configuration of the software should be depicted as below.
•Remove the SOM from the main board.
•Attach the JTAG programmer.
Note
Coprocessor and SOM must be upgraded with the same firmware version.

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•Apply mains power.
•Confirm green device voltage light is on, on the Flash Pro Programmer.
•Press the AUTO PROG button. Programming takes 3 seconds to complete.
•Remove JTAG Programmer.
Note- If the programming step fails, try repeating this step two or three times, as it may
work on subsequent attempts.
•Remove mains power
•DO NOT remove the backup battery
•Press and hold the OFF button until all LEDs turn off. STAT1 to STAT5 should all be
off.
•Insert the SOM.
4.3.5 Upgrade SOM after the Coprocessor
•Before continuing ensure that:
othe backup battery remains inserted
oSOM is inserted
oLAN cable is disconnected
•Insert the SD card containing the firmware.
•Apply mains power.
Hold FN5 and OFF buttons together until the STAT5 LED blinks fast. Release OFF
while continuing to hold FN5. STAT4 LED will come on.
•Only release FN5 when a red line is visible at the bottom of the WM screen.
•This must be performed immediately after pressing FN5. The USB flash media with
the customer configuration on it needs to be in the instrument when the upgraded
software first boots after installation.
•When the device screen indicates the upgrade is complete, remove the SD card
containing upgrade firmware.
•Conduct a reset of the instrument. FN5 should not be pressed.
oPress and hold OFF until the STAT5 LED fast blinks (~10.0 seconds).
Release OFF stat 4 will come on.
•The device will now boot into the new firmware.
Press FN1 and confirm the firmware version reflects the current version.
•Reconnect LAN cable if it was connected prior to conducting SOM upgrade.
4.3.6 Via USB
•Turn the Authorisation off.
•Insert blank SD card and leave in the WM when firmware upgrade is finished.
•Insert the USB containing the latest firmware into a vacant USB port.
Note
Coprocessor and SOM must be upgraded with the same firmware version.

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•Validating Software Update Package will show in the bottom left of the screen.
•Approval Required will appear on the screen once the software has validated.
•As prompted press the FN2 button.