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Intoxilyzer 5000 Service Manual (68 series

1. S601 SOLDER SIDE 0000 5609 5610 S611 5612 5615 P C B MAP li 11 ca 020867 NO Bill of Materials Assembly Number 020867 Assembly Desc PWB ASSY Switch Function REFERENCE COMPONENT COMPONENT CMI REPLACEMENT DESIGNATOR LOCATION DESCRIPTION PART NUMBER 601 E6 HOR STR 26PIN DUAL ROW 100CC 320167 601 608 D8 SWITCH DIP 8 SPST 300044 609 06 SWITCH SLIDE SPDT PC MT 300037 5610 D6 SWITCH SLIDE SPDT PC MT 300037 020867 PWB ASSY Switch Function Test Procedure Troubleshooting Tips Revision 1 3 11 Chapter 3 020725 Communications board Assembly General Description The communications board assembly provides an electronic connection between the I 5000 and external electronic instruments The external connections provided are serial communications at 300 1200 and 2400 baud rates factory preset external keyboard connection of either IBM or membrane varieties IBM is shown and an optional parallel printer port for an external Centronix compatible printer if an internal printer is not present The serial port and keyboard connects to the CPU board assembly through connector P701 Power for the IC s and external keyboard is connected by connector P702 The parallel printer port connects to the CPU board through connector P1 provided the external printer option is present Connector J701 is an industry standard 5 pin DIN conne
2. a BO Al HC245 HC 138 57 57 BOE m 75 8051AH O B255A HCO4 _ 98000 ASS T 5 m PWB 310186 PATT D 3 PATT D PWB ASSY MICROCONTROLLER 5000 020787 REV F Bill of Materials Assembly Number 020787 Assembly Desc PWB ASSY Microcontroller REFERENCE COMPONENT COMPONENT CMI REPLACEMENT DESIGNATOR LOCATION DESCRIPTION _ _PARTNUMBER C1 5 CAP CER 1UF 20 50V 410005 C10 CAP CER 1UF 20 50V 110005 C11 C6 10 20 50 110005 C12 C5 CAP CER 1UF 20 50V 110005 C13 C6 CAP TANT 1 0UF 905003 C2 D6 CAP CER 1UF 20 50V 110005 C3 E5 CAP CER 1UF 20 50V 110005 C4 C6 CAP CER 30PF 50V IC 300BCRO50K 110031 C5 06 CAP CER 30PF 50V IC300BCRO50K 110031 C6 C6 CAP CER 1UF 20 50V 110005 C7 C5 CAP CER 1UF 20 50V 110005 C8 C6 CAP CER 1UF 20 50V 110005 C9 D5 CAP CER 1UF 20 50V 110005 J1 E4 HDR STR 30PIN FLAT 100CC 320442 J2 D4 SOCKET IC 20 PIN DIP 30CC STR 320176 R1 C4 RES FILM 10 OHM 1 4W 196 904031 3 R2 C4 RES FILM 10K OHM 1 4W 196 904034 U1 E5 IC 74HC245AN BUS TRANSCEIVER 220138 U2 6 IC 8255A 5 PPI VO PORT 220089 U3 E5 IC P80C51FA MICROCONTROLLER 220146 U4 C7 IC 74HC373N OCTAL LATCH 220155 U5 C5 IC 27C512R 12DC EPROM 64Kx8BIT 220157 U6 C6 IC MK4864N 120NS SRAM 8Kx8BIT 220163 U7 D5 1C 74HC138AN 10F8 DECON DEMUX 220178 08 C5 1C 74HC08N QUAD INPUT AND GATE 220119 09 C6 74 04 HEX INVERTER
3. amp 4 6 0 4 0 2255 wean 4 OTT E lt e 5 2 gt 475 252 POTENTIAL 3 2 Kunn gt os gt lt 2 2 1 ta gt 52 9 e x u o 021 9256 D POTENTIAL JUMPERS T FIMSER de ca CN PRINTER A INVALID TEST S coo lt lt lt Late 64 66 amp 6 0 wma 9n K 260680608 phil 3223222522 lt LIST MEDID De 28 2 406352 Le 2 gt 22 Sunn 555994 3 ride x a Us o x o x a REFLECTIVE OBJECT SENSOR OPD 126A 25 x E 1 PAPER FEED 5 5 WEY d 181 Postion 5 Vai 3 V rita PUB 310120D 5 PRINTER BOARD 5888 ALL RESTETOR VALUES RAE ER onns wx 1 4U
4. Twv Intoxilyzer 5000 Service Manual 68 series Revision 1 3 4 20 95 Contents Chapter 1 Introduction General Description About This Manual Terms and Conventions Contacting Customer Service Part I System Circuit Descriptions Chapter 2 020867 Switch Board General Description Schematic Printed Circuit Board Map BOM Testing Procedure Troubleshooting Tips Chapter 3 020725 Communication Board Assembly General Description Schematic Printed Circuit Board Map BOM Testing Procedure Troubleshooting Tips Chapter 4 020524 Internal Printer Board Assembly General Description N Schematic Printed Circuit Board Map BOM Testing Procedure Troubleshooting Tips Chapter 5 020787 Controller Board Assembly General Description Schematic Printed Circuit Board Map BOM Testing Procedure Troubleshooting Tips Revision 1 3 2 QN tA Un 50 oo 96 12 12 13 14 15 16 16 19 20 21 22 22 25 26 27 Chapter 6 020785 Analog Processor Board 0 General Description Schematic Printed Circuit Board Map BOM Testing Procedure Troubleshooting Tips Chapter 7 020833 CPU Board Assembly General Description Schematic Printed Circuit Board Map BOM Testing Procedure Troubleshooting Tips Chapter 8 020860 020861 Mother Board Assembly General Description Schematic Printed Circuit Board Map BOM Testing Procedure Troubleshooting Tips Chapt
5. 200 004 internal 3 300 006 For those units with the internal printer option depress esc esc again Depress the p key whenever the function codes are displayed Insert the printer card and perform a printer check Carefully examine the printer card for the unit s serial number date e prom version time various functions and printed letters The last copy should be legible with all seven printer head pins striking hard enough to read easily The external printer option will print out one line of information including the alphabet numbers 0 through 9 and DAS Place all hard copies of the printed information and the quality control data sheet in a folder and place sequentially in the file cabinet Save the first copies of the printed cards for engineering review and data collection Turn power off to the intoxilvzer unplug the power cord and keyboard external printer if connected Place the compieted intoxilyzer on the final checkout station bench Revision 1 3 48 Various function menus displayed Display ch d i r q e Ch Single Channel Selection Continuous Stepping Of Channels D Values I Internal Standards R Auto Range Q Quit T Auto Calibration Routine Hidden Code Not Displayed when d or is selected the menu will reappear to allow selection of either single channel ch or stepping of channels c Display A B C D E F G H I K P
6. 21 Switch Board J103 Cpu Board 2119 Comm Board Power The cpu board should have the test prom 29 07 installed in socket u203 Turn power on A diagnostic check will be performed that wiil test the prom ram cell temperature processor output and printer f a problem exists in the processor board outputs the following error codes will be displayed a Processor error svnc pulse problems chopper wheel not turning b Processor error 2 sync pulse problems chopper wheel turing too slowly Processor error 3 b a c output drifting in a positive direction d Processor error 4 bac output drifting in a negative direction e Processor error 5 d v m reading 15 above 600 f Processor errors 5 4 and 5 wiil be displayed for 5 seconds then the dvm test value will displayed Wait until this reading is below 600 then depress the reset switch on the back of the test fixture After the diagnostic sequence is completed the date will be displayed Depress the start test switch again The dvm test will be displayed Turn the test fixture off then on again Depress the start test switch twice in rapid succession after the beep has sounded This wiil bypass the diagnostics checks The date will be displayed Depress the start test switch again The dvm will be displayed Depress the start test switch again The alphanumeric display should have l e d segments lit at this time Depress the start test
7. 3 a on e gt E lt om e m a 222 SP101 1 Qi 11111 1 101 P121 A ES 0000 0000 0000 3053 3223 2222 PATT J PWB ASSY MOTHER W TEMP CONT 020860 REV A M 020861 REV A 220V Bill of Materials Assembly Number 020860 Assembly Desc PWB ASSY Motherboard REFERENCE COMPONENT COMPONENT CMI REPLACEMENT DESIGNATOR LOCATION DESCRIPTION PART NUMBER __ C101 E7 ELCTLT 4700UF 50V 20 AXL 110121 C103 5 0010 50 110011 104 4 CAP CER 2PF 50V 110098 C105 C8 CAP TANT 68UF 25V 110007 C106 D6 CAP TANT 68UF 25V 110007 C108 B6 CAP TANT 68UF 25V 110007 C122 A4 CAP CER 001UF 50V 110011 C123 E7 CAP TANT 100UF 10V SCR13C 107KM 110109 C124 F7 CAP CER 033UF 50V CK05BX333K 110128 CR121 5 DIODE 1N4148 COMPUTER GRADE 210001 CR122 A4 DIODE 1N4148 COMPUTER GRADE 210001 F101 F6 FUSE PICO 5A LITTLEFUSE 251005 140023 F102 F7 FUSE PICO 7A 255007 140039 F103 F7 FUSE PICO 2AMP 276002 140038 i F104 C5 FUSE PICO 7A 255007 140039 J101 B5 CONN EDGE PCB DUAL22 156CC 320165 J102 D7 CONN EDGE PCB DUAL22 156CC 320165 J103 A5 SOCKET PCI 16 PIN USED 316T 320141 104 C6 CONN EDGE PCB DUAL10 156CC 320194 JMP101 EF6 JUMPER PREFMD 22GA INSL 30C C 330243 K102 DE6 RELAY SS PC MT 5VIN 120 240VOT 340031 K103 DE6 RELAY SS PC MT 5VIN 120 2
8. 65 LVPSRPO2 Printed by AULLD On 4 19 95 at 10 55 36 500 Buy Items Assembly 205686 INTOX 5000 110V KBD COM 2SOL List Component Description Price 101209 SCR 4 40x 590 PR PNH STL ZNM 250 401211 SCR 4 40x 250 ER PNH STL ZN 1 401212 SCR 4 40x 312 ER PNH STL ZN 10 101213 SCR 4 40x 375 HSH SET LKG SST 1 40 101214 SCR 4 40x 375 PR PNH STL ZN a 201216 SCR 4 40x 125 HSH SET STL IN 25 301220 SCR 4 40 250 HS BTNH STL EO 30 401224 SCR 4 40x 188 HS BTNH STL BO 25 301409 SCR 6 32x 312 HS BTNH 3TL EO 25 401412 SCR 86 32x 375 ER PNH _TL ZN i0 301413 SCR 46 32x 500 PR PNH STL ZN E 401415 SCR 6 32x 312 PR PNH STL ZN 10 401421 SCR 6 32x 312 PR FLH STL ZN 10 101423 SCR 5 32x 25 PR PNH STL ZN 10 101439 SCR 5 32x 750 PR PNH STL ZN 229 301443 SCR 6 32x 250 HS ETNH STL BO 25 401451 SCR 6 32x 875 PR FLH STL ZN 15 401601 SCR 8 32x 375 PR RDH STL ZN 10 401610 SCR 8 32x 250 PR RDH STL ZN 10 401616 SCR 8 32x 250 HS BTNH STL BO 10 401810 SCR 810 32x 375 PR PNH STL ZN 10 401812 SCR 10 32x1 88 PR PNH STL 2N 25 402501 TIE CABLE 6 6 NATURAL NYLx3 9L 10 402511 TIE CABLE 6 6 NATURAL NYLxS 6L 10 402523 CLAMP CABLE SCREW MT 375D 15 402545 RETAINER LAMP 3 85 402550 CLIP CHRISTMAS TREE SHD 16HL 35 408001 WSHR LK INT TOOTH STL ZN 4 10 408003 WSHR LK EXT TOOTH STL ZN 1 4 10 408005 WSHR LK INT TOOTH STL ZN 2 10 408018 WSHR LK INT TOOTH STL ZN 6 10 408019 WSHR RGL
9. PWB ASSY CPU REFERENCE COMPONENT DESIGNATOR LOCATION C1 D3 C10 D4 C11 C3 C12 B3 C13 D4 C14 C5 C15 16 B6 C19 C2 D3 C20 ES C21 D4 C22 D6 C23 D6 C24 D5 C25 D3 C27 B3 C28 C6 C29 D3 C3 C4 C4 C4 C5 D3 C6 C3 C7 D3 CR1 C6 CR2 C6 CR3 D4 CR4 B4 CR5 D6 CR6 6 J1 B7 J2 B6 J4 85 45 BS J6 B5 J7 B5 J8 B5 J9 E9 PS1 BC3 Q2 B3 R1 B7 R10 B3 R11 C4 R12 D4 R13 C3 R2 B7 R28 E7 020833 PWB ASSY CPU 020833 PWB ASSY CPU COMPONENT DESCRIPTION CAP TANT 2 2UF 20V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V 10 20 50 CAP CER 1UF 20 50V CAP VAR 7 40PF CAP CER 20PF SPRAGUE 5GAQ20 CAP CER 1UF 20 50V CAP CER 120PF CK05BX121K CAP CER 1UF 20 50V DIODE 1N4148 COMPUTER GRADE DIODE 1N4148 COMPUTER GRADE 1C LM336Z02 5 RGLTR NAT ONLY DIODE 1N746A ZENER 3 3V DIODE 1N4148 COMPUTER GRADE DIODE 1N4148 COMPUTER GRADE SOCKET IC 16 PIN DIP HDR STR 10PIN LKG 100CC HDR STR 02 PIN FLAT 100CC HDR STR 02 PIN FLAT 100CC HOR STR 02 PIN FLAT 100CC HDR STR 02 PIN FLAT 100CC HDR STR 02 PIN FLAT 100CC HOR STR 06PIN LKG 100CC BATTERY LITHIUM 3 6V 1 2AA XSTR 2N2222 NPN GP AMPL TO
10. RES FILM 1 MEG OHM 1 4W 5 RES FILM 3K OHM 1 4W 5 RES FILM 3K OHM 1 4W 596 RES FILM 100K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 1 MEG OHM 1 4W 5 RES FILM 1 MEG OHM RES FILM 3K OHM 1 4W 5 RES FILM 3K OHM 1 4W 5 RES FILM 1 MEG OHM 1 4W 5 RES FILM 1 MEG OHM 1 4W 5 RES FILM 3K OHM 1 4W 5 RES FILM 3K OHM 1 4W 5 RES FILM 1 MEG OHM 1 4W 5 RES FILM 1 MEG OHM 1 4W 5 RES FILM 3K OHM 1 4W 5 RES FILM 3K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K RES FILM 10K OHM RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 3 3 OHM 1 4W 5 RES FILM 3 3 RES FILM 3 3 OHM 1 4W 5 RES FILM 3 3 OHM 1 4W 5 RES FILM 3 3 OHM 1 4W 5 RES FILM 3 3 OHM 1 4W 5 RES FILM 3 3 OHM 1 4W 5 RES FILM 3 3 OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 68K OHM 1 4W 5 RES FILM 68K OHM 1 4W 5 RES FILM 10K RES FILM 10K OHM 1 4W 596 RES FILM 1 MEG OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 180 OHM 1 4W 5 200026 900193 900193 100014 100014 100014 100014 100017 100017 100059 100059 100014 100014 100014 100014 100017 100017 100059 100059 100017 100017 100059 100059 100017 100017 100059 100059 100010 100010 100010
11. V Q X Z A Air Blank B Breath Test C Calibration Test D Diagnostics Test E Preliminary Data Entry F Frequency Check Clock Adjustments G Gas Or Wet Bath Calibration Test H Dvm Test I Internal Standards Check K Flow Rate P Printer Test V Software Version Q Quit X Target Value Solution Value On Calibration Side Z Record Count 9 NOTES Revision 1 3 49 LVPSRPOZ Printed by AULLD 4 19 95 10 55 35 500 CMI INC Suy items Assembly 2295686 INTOX 2000 0V7 KBD COM 2SOL List Component Description Price 290001 ES FILM 100 2 4 53 30 220006 RES FILM 1X OHM 1 4 5 29 222015 BES FILM 10K 3 5 22 220013 RZS FILM 68K CHM i 4W 55 27 220014 PES FILM Jaw 2 229017 BES FILM 1 08 1 45 5 29 150018 RES FILM 180 1 4 5 29 220019 RES FILM 22 OHM 1 4W 5 29 220025 RES FILM 5 1X 2 48 5 30 200034 RES FILM 470K OHM 1 4W S 39 220047 RES FILM 82K OHM 1 4W 5 30 100059 RES FILM OHM 1 4W 5 30 220065 RES FILM 10 1 4 5 25 200066 RES 3 3 OHM 1 4W 5 30 121013 HTR SIL RUB 129V 72W 1 x15 L 13 30 101030 HTR 15W 120V 5 8x30 00630081 13 80 291073 ETR 15V 9 5W W EBONO PLUG 49 10 391078 RES WW 2 OHM 1 57 2 90 202014 POT CERMET MT END ADJ 50K 3 60 102028 POT CERMET PC MT TOP ADJ 10K 2 20 202031 POT CER
12. down position Testing Procedure Turn power on Note if there is a noticeable power suppiy squeal or if the 1 7 Source is not lit turn power off and troubleshoot the various input power busses to the board 2 The display should read ready to test the printer will move to the right if it is not positioned there at the beginning of the test Depress the start test switch The display will show ps on at tone and a constant trequency tone will be heard Activate the pressure switch either manually or by blowing into the cell chamber tubing The display will show turn ps off Then ps on at tone again after the pressure switch is deactivated The constant tone should be a higher pitch than the tone heard at the initial ps on at tone mode Blow into the ceil tubing again to turn tone off Whenever the display reads print inhibit on set switch s613 on the switch board to the up position print inhibit or wiil be displayed Switch s613 up and down until turn head switch on is displayed Operate the cherry switch lever up and down and verify that the display will indicate that the head switch ts off then on then otf The display shouid read insert card now Verify that the printer feed motor is turning smoothly and not chattering excessively insert the printer card into the printer slot The card should advance smoothly and eveniv into the printer A print test will now be performed Th
13. 100010 100010 100010 100010 100010 100010 100066 100066 100066 100066 100066 100066 100066 100066 100010 100014 100013 100013 100010 100010 100017 100010 100010 100018 R366 R367 R368 R369 R370 R371 R372 R373 R374 R375 R376 R377 R378 R379 R380 R381 R382 R383 R384 R385 R386 R387 R388 R389 R390 U301 U302 U303 U304 U305 U306 U307 U308 XU301 XU302 XU303 XU304 XU305 XU306 XU307 XU308 020524 PWB ASSY Printer D5 U301 E5 U302 D5 U303 E4 U304 04 0305 C4 U306 C5 U307 B5 U308 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 100 OHM 1 4W 5 RES FILM 1K OHM 1 4W 5 RES FILM 1K OHM 1 4W 5 RES FILM 1K OHM 1 4W 5 RES FILM 1K OHM 1 4W 5 RES FILM 1K RES FILM 1K OHM 1 4W 5 RES FILM 1K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 1C 8255A 5 PP PORT 1C CD4069BE NATIONAL ONLY 1C CD4069BE NATIONAL ONLY IC LM339 QUAD VOLT COMPARATOR IC LM339 QUAD VOLT COMPARATOR IC CO4069BE NATIONAL ONLY IC 4066 QUAD BILATERAL SWITCH IC 4066 QUAD BILATERAL SWITCH SOCKET IC 40 DIP 60CC STR SOCKET IC 14 PIN DIP 30CC
14. 74HCO8N QUAD INPUT AND GATE 1 10 220124 IC 74HCO4N HEX INVERTER 1 10 220134 UPD43256BCZ 70L CR 24 85 220135 T2 MM58274 REAL TIME CLOCK 33 85 220136 2ZC 74HCT04N HEX INV W LSTTL 55 220138 2 BUS TRANSCEIVER 2 95 220140 IT T4HC244AN OCTAL BUFFER 1 65 220141 22 72 14 HEX SCHMITT INVERT 1 10 220144 12 12 BIT 2 0 CONV MAXIM 51 25 2VPSRP02 Printed by AULLD tn 4 19 95 500 CMI INC Assembly 000568G INTOX 5000 119Y XBD COM 2SOL Component Description 120145 IZ2 MAX695CPE MICROPROC FESET 220146 P8BOCSIFA MICROCONTROLLER 119149 12 46 SERIAL ZEFFOH 220154 IC MC74HC154N 4 1 ICODER 220155 IC 74HC373N OCTAL LATCH 2292154 IC AD7524JN D A MUL 220163 IC MK4864N 120NS SRAM 8Xx8BIT 220165 IC PALCE20V8Q 15PC PRGM LOGIC 220166 IC 28406 NMOS 280 4 2 220167 IC 28440 NMOS SIO CNTRLLE 220178 74HC138AN 10F8 DECON DEMUX 230013 RGLTR LM340T12 12V TO220 230014 IC LM320T12 12V RGLTR 230022 IC CA3140E MOS FET OP AMP 230030 IC LM336202 5 RGLTR NAT CNLY 230035 IC DS1488N QUAD LINE DRIVER 230036 IC DS1489N QUAD LINE RCVR 230046 IC CA3079 ZERO VOLTAGE SWITCH 230053 IC DG212CJ 4 CHAN SPST ANGL SW 230054 IC TLO034ACN OP AMP 230056 IC CA3280E OPNL XCNDCT AMPL 230066 IC LMC660CN CMOS QUAD AMP 230067 IC 74HCT4052 ANALOG MUXIDEMUX 290037 SWITCH SLIDE SPDT 200044 SWITCH DIP 8 SPST 300050 SENSOR REPLECTIVE 300057 SWITCH ROCK
15. 8 STR BHD 210197 FITTING TEE 4 85 410194 FTG QUICK CPLG BARBED 275 DIA 20 20 410195 FITTING ELBOW 3 8 12 05 410196 COUPLING 2 35 440087 BRKT LAMP 4 70 440150 STDF SST F F 250Dx 25L 46 32 1 65 440250 BRET THERMOSTAT 5000 28 70 140263 BRKT INTOX 5000 FRINTER REV B 24 60 440272 BRKT BREATH HOSE 5 60 440279 STDF SST F F 25HEXx 38L 36 32 22085 440285 BRKT INTOX 5000 FAN MTG 19 45 440302 BRKT 5020 SWITCH BD REV 2 50 440313 BRKT 5000 SOLENID TWO 21 00 440370 BRKT PANEL FRONT 5000 26 70 140378 BRKT SPEAKER 5 25 440382 COVER SWITCH 5000 4 35 440383 COVER 5000 50 90 440385 PANEL WELDMENT BOTTOM CASE 26 55 440386 COVER FRONT CASE 5000 42 10 440458 PLATE END 5000 8656 221 00 340459 COVER TEST RH END PLT 5000 14 85 440460 BRKT CONN 0 5200 25 30 440489 FILLER FILTER CHOPPER WHL 1400 1 4 440490 BRKT CELL MTG SOURCE END X68 7 35 440534 ZNCL CHOPPER WHEEL 54200 68 26 70 440535 SPCR SST 250Dx 125IDx 25L 1 20 440549 ARKT PROC MTG CW 5000 68 298 25 440555 HEATSINK XSTR PRCSR 5000 68 2 65 40551 STDF SST M F 25HEXx 25L 36 3 2 30 340552 STDF SST M F 3HEXx 56i 76 32 2 20 240554 SOURCE MTS 2 45 340555 HUB CHOPPER 25827 140556 HEEL CHOPPER Sutc 53 22 80 440560 ERKT SENSOR PRESSURE 2 45 40565 3TDF zST FP P 5HENx 938L l 2430 140569 3RKT HOLD DOWN PSs Tage LVPSRPO2 Printed by AULLD 4 19 95 10 55 36 500 MI INC Buy Items Assembly 5
16. 90 230019 KTAL LF 32 758KH2 7 45 230024 TAL 12MHZ M TRON 2 50 230025 1 2 12 65 240023 FUSE PICO SA LITTLEFUSE 151095 1 40 140029 DISPLAY IEE 31922 03 171 60 240037 FUSE 3AG 3AMP 250V 55 140038 FUSE PICO 2AMP 276002 2 40 140039 FUSE PICO 7A 255007 1 40 140040 SOURCE IR COATED NEP 38 80 140058 FUSEHOLDER PNL HT LOW PROFILE 4 70 140075 INTERRUPTER OPTEK OPB840WS5 5 90 150010 SPEAKER MSC 300T 5 50 i60008 FILTER OCLI 3 489 MICRONS 35 50 260010 FILTER OPTICAL 3 38 MICRONS 35 50 160012 LENS ASPHERIC POLY IRS i 45OAD 14 85 160013 FILTER OCLI 3 80 MICRONS 35 50 200026 XSTR 4861 JFET 1 65 200038 XSTR TIP122 DAR PAIR 85 200040 XSTR TRIAC 4 0 AMP TO 220AB 4 40 200052 XSTR 2N2222 NPN GP AMPL TO 18 55 210001 CIODE 1N4148 COMPUTER GRADE 30 210002 DIODE 1N4001 30 210023 DIODE 1N746A ZENER 13 3 30 210056 PC6 90 TEMP SWITCH MTS 40A 2 21 20 210058 THERMISTOR JA41J1 5 25 210061 RECTIFIER BRIDGE VH24B 3 85 210065 VARISTOR GE V130LA10AMOV 85 210078 DETECTOR PBSE SGL STAGE COOLNG 610 50 210082 DIODE PAD100 SILICONIX 4 70 210086 SENSOR SCX15AN PREC COMP PRESS 70 20 220035 IC LM311 VOLTAGE COMPARATOR 90 220036 IC LM339 QUAD VOLT COMPARATOR 255 220056 IC CD4069BE NATIONAL ONLY 55 220070 IC 4066 QUAD BILATERAL SWITCH 55 220089 8255 5 PPI I O PORT 8 80 220096 Ic ADC1001CCJ 1 A D CONVERTER 42 90 220098 ZI MC14503BCB MOTOROLA ONLY 55 220101 IT MC145411 BIT RATE GENERATOR 3 85 220119 ZI
17. DIP 30CC STR SOCKET JC 14 PIN DIP 30CC STR 14 PIN DIP 30CC STR 14 DIP 30CC STR 14 PIN DIP 30CC STR RES NET 10P SIP 9 100K 1 8W 2 210061 200040 100065 100065 100065 100065 100065 100065 100065 100065 100065 100065 100065 100065 100065 100065 100065 100065 100014 100013 100034 100059 100014 100014 100010 102014 100010 103042 103043 103044 102028 103045 100010 100010 100010 100010 150010 220098 220098 220098 220098 220035 220056 220056 230046 220136 320141 320141 320141 320141 320182 320181 320181 320181 320181 103050 020860 PWB ASSY Motherboard A7 RES NET 10P SIP 9 100K 1 8W 2 BRKT SPEAKER PWB MOTHER W TC 5000 REV J SCR 4 40x 312 PR PNH STL ZN SCR 6 32x 25 PR PNH STL ZN SOCKET MINTR SPR 026 033PD SPRT NYL PCB 31HEXx 25L 6 STDF SST F F 250Dx 25L 6 32 TIE CABLE 6 6 NATURAL NYLx5 6L TUBING SHRINK 1 2 DIA WSHR NAR PLAIN NYLON NAT 6 103050 440378 310143 401212 401423 320134 410084 440150 402511 520022 408035 pete EQUIPMENT REQUIREMENTS Test 5000 Intoxilyzer With Tested Boards e Oscilloscope Hitachi V152 B Or Equivalent e Digital Voltmeter Keithley 175 Or Equivalent Test Eprom 29 07 TESTING METHODS Preliminary Checks Setups 2 tn Caretullv inspect the mother board to be tested for any obvious problems such as solder oridges missing components r
18. Port B drives an inverter U304 U305 which in turn drives a comparator The inverter is used to buffer the signal into the comparator The comparator is used as a level translator because a high digital signal Revision 1 3 17 5 volts on the output of the inverter will provide a 15 volt signal at the output of the comparator A low digital signal on the output of the inverter will thanks to the resistor network connected between the inverting input of the comparator and the output of the comparator result in a 15 volt signal on the output of the comparator The output of the comparator is used to hard drive darlington power transistors which connect either side of the center tapped stepper motor coil to 15 volts The diode and resistor combination connected to each of the printer coil are used to dissipate the power remaining in the coils when the coil is turned off This free wheeling configuration prevents the surge current from destroying the PN junction in the power darlingtons Revision 1 3 18 y LJ z md nd ai REE ee Bi de Thi PRINTER P303 _HESD b RITE lt a lt 24 7 gt 25 a 2 TEST 22222222 cooo lt lt lt lt lt lt lt
19. RES FILM 681K OHM 1744 1 239 204123 RES FILM 9 09K OHM 1 4W 1 39 804187 RES FILM 1 5M OHM 1 4W 5 25 205003 CAP TANT 1 0UF 55 305004 CAP TANT 2 77 2 95 205023 CAP CER 100 PF S00V 30 305031 CER 470 500 30 395065 AP METAL 5 120 35 206410 WIRE HOOK UP 18AWG ELK 29 906415 WIRE HOOK UP 18AWG WHT RED 220 206601 IRE ZZGA BRN UL 2297 36 306602 WIRE 22GA RED UL 1507 90 506604 WIRE 22GA YEL UL 1297 50 306607 WIRE 22GA VIOLET UL 1007 90 206608 SIRE 22GA GRAY UL 2297 20 206609 WIRE 22GA WHITE UL 2207 00 306610 NIRE 22GA BLACK UL 1907 29 306614 NIRE 22GA WHT BLK VL 1007 VW 1 22 206615 NIRE 22GA WET RED UL 1007 29 206805 WIRE 18GA GRN UL 2227 29 206813 WIRE 18GA BLK UL 2227 220 206815 WIRE 18GA WHT RED CL 1207 299 OTT TUBING SHRINK ZLZ 220 1 226 73 Pace
20. eprom is accessed by the 8051 through the use of the signals PSEN and ALE The transparent latch is latched and unlatched by the signal ALE The eprom is accessed by a low level signal on PSEN When PSEN is low the next instruction is fetched from the eprom ALE will transition from high to low midway through the PSEN pulse While ALE is high and PSEN is low data the next instruction is read from the eprom This process continues in a cyclic fashion as the program is executed The chip labeled U6 6164 is an 8 K x 8 bit static RAM chip The purpose of the RAM in this configuration is to provide the microcontroller with more scratch pad memory than is available on the 8051 The 8051 provides only 256 bytes of RAM space on chip which is not enough to handle all the computations and variables need to successfully complete our task The external static RAM chip is treated as an external peripheral chip as it is attached directly to the subsystems address data bus Both temporary variables as well as the working calibration information is stored in the external RAM for easy access by the microcontroller The chip labeled U7 74HC138 is a 3 bit to a one of eight address decoder demuitiplexer chip Address information is supplied to the chip through pins Revision 1 3 23 one through three by address lines A13 A14 and 15 Each of eight outputs on the chip will move to a low state corresponding to the address on the inputs The decoder chip there
21. is comprised of 4 gates of U306 2 resistors and a capacitor The nominal frequency of the oscillator is 1 KHZ This frequency is changed when the resistor R359 is added to the feedback path around one of the inverters An example of this frequency shifting can be heard during an error condition such as an invalid sample Card Present and Left Side Detect Card present and printer head left side detect are connected to printer sensors through connector P302 Both signals are inputs with card present traveling first through an inverter then into PC1 while left side detect simply has a pull up resistor to go directly into PCO The card present signal is generated by an optoreflective sensor located on the printer which senses the presence of a print card The left side detect signal is generated by a SPST switch which is mechanically activated as the head reaches the left side carriage return position Printer Head Drivers The seven printer head drivers are located near the center of the schematic Each driver controls one pin of the 7 pin printer head All seven drivers are identical so only one is described here Port A of the 8255 is dedicated to driving FET switches contained in IC s U307 and U308 The bilateral switch chip 4066 contains four SPST FET E switches used in this application to provide a layer of isolation between the 8255 and the darlington power transistors When the FET switch is closed the darlington transistor Q301 turns on
22. r17 as necessary to obtain the correct voltage at u2 7 b test point Place the tvgon tubing onto the a port of 22 Create an altitud e change by sucking slightly on the tubing The voltage at the b test point snould decrease If the flow rate option is installed on the board adjust r20 for an off set voltage of 450 vdc at test point f Place the tygon tubing onto the b port ot zl Blow gently into the tubing and verify that the voltage at test point goes in a positive direction Turn power off to the unit under test Remove the tygon tubing from 21 or z2 b Remove the unit under test from the test fixture Place a test label under the board revision marking Record your initials month year and work order on the label Place the tested board in a static proof bag container or carrier before any other handling is pertormed Options Board Assemblv 020855 Part II Final Instrument Testing Procedures e Chapter Il Final Unit Test Procedure 41 e Chapter 12 Instrument Calibration Procedure 42 Revision 1 3 44 Revision 1 3 45 Chapter 11 Final Unit Test Procedure Chapter 12 1 Instrument Calibration Procedu Equipment requirements y 1 ete Fluk 80 0a O q iva D gita Voltm ter 5 u len Troub eshootin Pu oses Wet Bath Simulators With Various Solution Values Hao Water Reference 020 Brac 040 Brac 080 Brac 100 Brac 150 Brac High Acetone 100 Bra
23. switching one side of the individual print head pin s solenoid to ground through a 2 amp resistor The other side of the solenoid is connected to 40 volts generated by a separate transformer located opposite the main power supply in the instrument The result is the printer pin being thrust towards the paper making the familiar impact sound of a dot matrix printer The 2 amp fuse is intended to save the circuits and or the print head in the event that a power surge coil short or other fault condition should occur Stepper Motor Controllers The two stepper motor control circuits located on the far right of the schematic are used to drive both the card feed stepper motor and the head position stepper motor of the internal printer The basic concept of a stepper motor is that it can be rotated in steps either clock wise or counter clockwise Each motor has two coils which are center tapped The center tap is connected to ground on each coil of the motor By alternately connecting power to one side of the coil or the other the motor can be made to step in one direction The size of the step is usually measured in degrees of outward rotation or 360 degrees which would be a complete rotation With this basic understanding of the stepper motor the drive circuit can be more easily described Port B of the 8255 is used to control both stepper motors Only one of the stepper motor drive circuits is described here since both are identical Each pin of
24. test switch the using the esc esc i keyboard routine When prompted for the number of solutions depress the 0 key Insert the printer card when prompted by the display The printed card should show the a d dvm constant signal voltage y intercept slope and acetone subtract values Observe the display for the correct time and date If time and date is incorrect depress esc esc rapidly on the keyboard The display should show the various function modes of the software Depress the e key preliminary test data then enter as necessary to get to the time time zone date and location inputs Make any changes that may be appropriate If the intoxilyzer has the flow rate option call up this option k with the esc esc routine Turn the power supply to the pump on Adjust the voltage to the pump until the ball in the gilmont d 7093 flow meter is stabilized at the 14 reading 5 00 l min Whenever the operator is prompted to set for the 10 press button command connect the output of the flow meter to the breath hose Press the start test switch to enter this value into storage in the ee prom Repeat this procedure for the 27 readings 10 0 l min And the 39 readings 15 0 l min On the flow meter The correlation coefficient printed out should be 0 998 or greater If the gas calibration option is in the unit depress esc esc and then the g key for gas or wet bath calibration Depress the w key for wet bath checking Set swit
25. 0 081489 11 U1 D UR1488 PWB 318167E EXT PRNTR COMM 828725 REU J gt x a a 58088 OPTIONAL U2 D 041489 11 PWB 318167E EXT PRNTR COMM 5888 828725 REV J PWB 310167 PATT E Pi 020725 REV__ 1 55 5000 020725 REV J ee a ee poe Bill of Materials Assembly Number 020725 Assembly Desc PWB ASSY COMM REFERENCE COMPONENT COMPONENT CMI REPLACEMENT DESIGNATOR _ LOCATION DESCRIPTION PART NUMBER C1 D6 CAP CER 1UF 20 50V 110005 C2 D6 CAP CER 1UF 20 50V 110005 C3 D6 CAP CER 1UF 20 50V 110005 J2 D5 RCPT R A FEM DB25 BD PNL MT AP 320209 J701 D6 RCPT FEM DIN SPOS PNL MT 320363 J702 D6 RCPT R A FEM DB25 BD PNL MT AP 320209 P1 D5 HDR R A 26PIN LKG PC 320364 P701 D6 HDR R A 10 PIN LG 100CC 320195 P702 05 HDR R A 04PIN LKG 156CC 320417 P703 D6 HDR R A 02PIN LKG 156CC 320101 P704 05 HDR R A 02PIN LKG 156CC 320101 Q1 05 XSTR TIS97 900193 R1 05 RES FILM 10K OHM 1 4W 5 100010 R2 D6 RES FILM 10K OHM 1 4W 5 100010 01 D6 IC DS1488N QUAD LINE DRIVER 230035 U2 D6 IC DS1489N QUAD LINE RCVR 2300368 XU1 SOCKET IC 14 PIN DIP 30CC STR 320181 2 14 PIN DIP 30CC STR 32018T BRKT CONN KYBD 5000 440460 LABEL COM BRKT 5000 866 450137 NUT KEP STL ZN 4 40 400021 5000 866 310167 SCR 4 40x 250 PR PNH STL ZN 401211 SCREWLOCK CONN AMP P N207
26. 005686 INTOX t200 110V7 KBD COM 2SOL List Componenc Description Price 340571 REAR CABINET 57 75 240578 LATE END LH 50690 686G 221 00 14057 BARREL CELL SHORT 820 7 33 9 440584 FTG QUICK DISC FEMALE 1 4 29 35 440742 BLOCK END CELL 40 30 440745 BRACKET POWER SUPPLY 758VA 23 45 440749 PLATE PWR SUPPLY 758VA 5 60 440804 BRKT CARD GUIDE SUPPORT 00 440805 SRKT CARD DET amp GUIDE 00 450098 LABEL 2 SOL REAR PORTS 5000 55 450100 LABEL SW FCTN PDE TDE S000 2 20 450111 LABELS COMPLETE SET 5000 3 30 450167 TAG 5 5000 68 5 460057 GUARD SE PB SQ 10 75 460059P001 FACEPLATE INTOX 5000 15 95 460072 STRAP 6 60 470094 TUBING THEROZIPx10 5 9 95 470085 INSULATOR TO220 30 470088 SEAL CELL 85 470090 PAD SHOCK DISPLAY 50000 1 40 470100 SCREEN DISPLAY 5000 8 55 470101 SCREEN FAN 5000 6 60 470145 CAP PLASTIC 25IDx 50LG GREEN 2145 470154 CAP PLASTIC 4061 37516 RED gl 470155 CAP PLASTIC 843IDx 500LG RED LS 520019 TUBING SHRINK 1 8 DIA 210 520011 TUBING SHRINK 3 16 00 520012 TUBING SHRINK 1 4 D 00 520017 TUBING SHRINK 3 8 DIA 00 520022 TUBING SHRINK 1 2 DIA 10 520049 TUBING SHRINK BLK 75 DIA 1 50 520050 TUBING SHRINK BLACK 1 DIA 00 520057 CABLE ASSY SLAVE LINK 8 45 520058 TUBING 3 B8 ID 1 20 530013 TUBING TYGON 250IDx 3750D 2 50 530018 TUBING TYGON 188IDx 312CD 1 40 530023 HOSE 1 8 1 00 530030 TUBING TYGON 3751Dx 5620D 6 48 560010 TAP
27. 06 A6 U107 F7 U108 6 0109 7 020860 PWB ASSY Motherboard RECTIFIER BRIDGE VH24B XSTR TRIAC 4 0 AMP TO 220AB RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 10 OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 68K OHM 1 4W 5 RES FILM 470K OHM 1 4W 5 RES FILM 3K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 POT CERMET PC MT END ADJ 50K RES FILM 10K OHM 1 4W 5 RES WW 10 5 5 RES FILM 2 21K OHM 1 4W 1 RES FILM 475 OHM 1 4W 1 POT CERMET PC MT TOP ADJ 10K RES 3 16 0 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K OHM 1 4W 5 RES FILM 10K 0 SPEAKER MSC 300T IC MC14503BCB MOTOROLA ONLY IC MC14503BCB MOTOROLA ONLY IC MC 14503BCB MOTOROLA ONLY IC MC14503BCB MOTOROLA ONLY IC LM311 VOLTAGE COMPARATOR IC CD4069BE NATIONAL ONLY 4069 NATIONAL ONLY IC CA3079 ZERO VOLTAGE SWITCH 74HCTO4AN HEX INV WILSTTL SOCKET PCI 16 PIN USED 316T SOCKET PCI 16 PIN USED 316T SOCKET PCI 16 PIN USED 316T 16 PIN USED 316T SOCKET IC 8 PIN
28. 0V CAP CER 1UF 20 50V CAP CER 1UF 20 50V DIODE 1 DIODE 1N4001 DIODE 1N4001 DIODE 1N4001 DIODE 1N4001 DIODE 1N4001 DIODE 1N4001 DIODE 1N4001 DIODE 1N4148 FUSE PICO 2AMP 276002 2 276002 2 276002 2 276002 FUSE PICO 2AMP 276002 FUSE PICO 2AMP 276002 FUSE PICO 2AMP 3276002 HDR STR 08PIN FLAT 100CC HDR STR 06 FLAT 100CC HDR STR O6PIN FLAT 156CC HDR STR OSPIN LKG 156CC BRKY XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIP122 DAR PAIR XSTR TIS97 110037 110030 110005 110005 110005 110005 110005 110005 110008 110005 110005 210002 210002 2100027 210002 21 0002 GI 210002 210002 210002 210001 140038 140038 140038 140038 140038 140038 140038 320084 320100 320014 320027 200038 200038 200038 200038 200038 200038 200038 200038 200038 200038 200038 200038 200038 200038 200038 900193 CMI REPLACEMENT PART NUMBER 020524 PWB ASSY Printer XSTR 4861 JFET XSTR TIS97 XSTR TIS97 RES FILM 100K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 100K OHM 1 4W 5 RES FILM 1 MEG OHM 1 4W 5
29. 18 RES NET 10P SIP 9 100K 1 8W 2 RES FILM 22 MEG OHM 1 4W 5 RES FILM 100K OHM 1 4W 1 RES FILM 1 0K OHM 1 4W 1 RES FILM 20K OHM 1 4W 1 RES NET 10P SIP 9 100K 1 8W 2 RES FILM 10K OHM 1 4W 1 CMI REPLACEMENT PART NUMBER 110104 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110005 110123 110032 110005 110097 110005 900188 900188 230030 210023 900188 900188 900208 320184 902458 902458 902458 902458 902458 902303 340035 200052 103050 100019 904033 904055 904060 103050 904034 EQUIPMENT REQUIREMENTS Test 568 Intoxilyzer With Tested Boards Digital Voltmeter Keithley 175 Or Equivalent Oscilloscope Hitachi V202 Or Equivalent X10 Scope Probe Test Keyboard At Model Or Equivalent Test Eprom Oregon i029 Version 0002 Michigan 1005 Version 0001 Printer Cards 015010 TESTING METHODS Preliminary Checks Setup Carefully inspect the cpu board for anv obvious problems such as solder bridges missing components reversed components cold soldered joints unsoidered joints component lead flagging etc Extreme care should be taken on any repairs made since this is a multilayer board l La Verify all i c s are the correct ones and oriented properly Carefully insert the test eprom into u2 socket Check that no pins are bent or damaged Solder the lithium battery 3400
30. 18GA BLUx14 00 L W 125 WIRE 18GA RED WHTx15 0 L 5 125 WIRE 18GA GRN WHTx15 0 L 5 125 NIRE 18GA VIO WHTx6 0 L 4 003 WIRE 20GA REDx8 00 L W 016 WIRE 20 BLUx8 0C L W 016 WIRE 206 BLKx8 00 L W 016 WIRE 18GA GRN WHT 7 0 L W 125 WIRE 18GA RED WHT 9 0 L 4 125 WIRE 20GA BLKx3 50 L W 003 WIRE 18GA REDx7 50 L W 016 IRE 18GA BLKx8 50 L W 015 WIRE 18GA BLKx8 00 L W 016 WIRE 18GA REDx8 00 L 016 WIRE 20GA REDx15 50 L 6 6 WIRE 20GA ORGx15 50 L w 016 SIRE 20GA REDx16 50 L W 016 WIRE 20GA BLKx16 50 L W 016 WIRE 20GA BLKX15 50 L W 016 TUBING EXPANDABLE 3 4 CABLE ASSY PWR COMM 5000 68 HARNESS PWR SPLY TO MB 768 WIRE 18GA GRNx9 0 L W 125 PUMP MAG VIBRATION 115V 60HZ MOTOR 12V MABUCHI EG 530AD 2B PRINTER TDC CORP 8540 101178 7ALVE SOL OPER 110V RELAY S5 PC MT SVIN 126 240VOT BATTERY LITHIUM 3 5V 1 2AA TAN 1 7 3 15 2202 NUT HEX STL ZN 2 56 NUT KEP STL ZN 8 32 NUT ZEP STL ZN 6 32 NUT REP STL EN 10 22 STL NUT STL ZN 6 32 SCR 2 56x 375 PR RDH STL ZN 3 4 SDH STL oN 4 19 95 INTOX 5600 1107 KBD COM 2SOL List Pric au bi w A vo u qu an ity A oou Li Gi mw im 6 te ul 0 oo o co Pau
31. 20 vac input line Set the power on off switch to the on position The meter should read 20 0 vde 2 0 vdc 2 Check that the three switches are in the off position Leave the black meter lead in the 15 0v test point Move the red meter lead to the test points 702 2 702 4 and j702 20 The meter should read less than 1 5 vdc Switch si to the on position J702 2 should read 30 0 2 0 vdc j702 4 and j702 20 should still read less than 1 5 vdc Turn si off Turn 52 3702 4 should read 30 0 vdc 2 0 vdc j702 2 and j702 20 should read less than 1 5 vdc Turn s2 otf ua Turn 55 on 1702 20 should read 30 0 vde 2 0 vdc 702 2 and 702 4 should read less than 1 5 vdc Turn s3 off Connect the digital voltmeter to the tp 2 test point on the board positive lead and to ground negative lead The voltage at tp 2 should be approximately 3 0vdc Depress the switch on the keyboard adapter cable The voltage at tp 2 should go to approximately volts Release ine switch Cn Comunication Board Assembly 020725 Set the on off switch to the otf position Remove ail connectors trom the unit under test Place a test label near the marking of j701 Record your pay number the month year the board passed test and work order number if known Place the tested board in a static proof bag before anv other handline is pertormed Comunication Board Assembly 020725 Chapter 4 020524 Internal Pr
32. 220124 XU5 BC5 SOCKET IC 28 PIN DIP 60CC STR 320219 Y1 D6 XTAL 12MHZ M TRON 130024 PWB MICRCNTRLLR 5000 568 PAT D 310186 020787 PWB ASSY Microcontroller EQUIPMENT Test 568 Intoxilyzer With Tested Board Digital Voltmeter Keithley 175 Or Equivalent Oscilloscope Hitachi V202 Or Equivalent X10 Scope Probe Test Keyboard Xt Model Or Equivalent TESTING METHODS Preliminary hecks Setup Carefully inspect the microcontroller board for obvious problems such as solder bridges missing components reversed components cold soldering joints unsoidered joints lead flagging etc Use extreme care any BR je si his i itil i Verify that the 5 0 v 15 0v and 15 0v busses not shorted to ground or to each other The 15 0v and 15 0 busses should read infinity when checked to ground la Place the test software into u5 socket Be careful to that the i c Orientation is correct Connect the microcontroller board to ji on the processor board 122 Connect the slave cable to j2 tne microcontroller board Test Procedure Turn power If there is a noticeable power supply squeal or the Source is not lit turn power off and troubleshoot the various power busses Check for 15 0 vdc at j7 4 15 0 vdc at j7 3 and 5 0v at j7 2 on the multichannel processor board 1 2 Check that the voltage drops across r50 on the processor board does not exceed 1 8 vd
33. 35 into the ps holes on the board Be careful to observe the correct polarity Connect the interconnection ribbon cable from the mother board j103 to jl on the cpu board Place two shunt jumpers 320486 onto 14 and j6 baud rate pins Seat the jumpers properly 5 Insert the cpu board into the mother board connector Connect the keyboard cable to j2 and the slave cable trom the microcontroller board to socket Test Procedure Turn power on If the i r Lamp does not come on or if there is a noticeable power supply squeal turn power off and troubleshoot the various input power busses on the board 1 The intoxilyzer display will indicate a clock error not ready mode do an air blank indicate another clock error then go to a warm up period mode of operation The warm up period will normally take approximately twenty 20 minutes for a cold start initially After the cell warmed up sufficiently repeated board testing will not take as long Depressing the reset switch will also reduce the software waiting time After the intoxilyzer comes out of the warm up period a diagnostics check on the prom ram temperature processor and software version wiil be performed A processor fail will be flagged for processor 7 8 9 a then the channel signals of 000 or 4095 and noise of 000 readings Depress the esc key repeatedly until the display ch d i q D
34. 35V CMI REPLACEMENT PART NUMBER 110007 110005 110061 110005 110128 110061 110005 110061 110005 110100 110005 110005 110038 905023 905023 110005 110061 110099 110005 110005 110005 905065 110005 110005 110005 110114 110061 110061 110061 905031 110005 110005 110005 110061 110005 110005 110093 110061 110061 110005 110005 110093 110061 110093 EQUIPMENT 4 k ES Test 568 Intoxilyzer With Tested Boards Digital Voltmeter Keithley 175 Or Equivatent Oscilloscope Hitachi V202 Or Equivalent 10 Scope Probe Test Keyboard Xt Or Equivalent e Soldering Iron TESTING METHODS Preliminary Checks Setup Caretully inspect the processor board for any obvious problems such as solder bridges missing components reversed components cold soidered joints unsoidered joints etc Extreme care should be taken on any repair since this js a muiti bo i Verify all i c s are the correct ones and oriented properly Verify that 1 is LM340 12 12 0 vdc and VR 2 is a LM320 12 12 0 vdc regulator 2 Place a heat sink on the collector or Q6 Connect the test jumper from J5 2 to J5 3 G2 4 Connect the test microcontroller board to J Place the processor board into the test 568 unit Connect the input power connector to J7 Secure the board to the test 568 unit with only one screw at the top center of the board Verify that the heat ink of
35. 40VOT 340031 1101 5 COIL 1MH 5 160MA 19 OHM DCR 120012 P101 F7 CONN MTHR BD PRESSURE CKT 320488 P103 B6 HDR STR 03PIN LKG 156CC BRKY 320030 P104 C8 HDR STR 02PIN LKG 156CC BRKY 320114 P105 E7 HDR STR 02PIN LKG 156CC BRKY 320114 P106 E7 HDR STR 07PIN LKG 156CC BRKY 320105 P107 F7 HDR STR 03PIN LKG 156CC BRKY 320030 P108 F6 CONN 02 PIN MALE 320122 P109 F6 CONN 03 PIN MALE 320124 P110 7 CONN MALE PC 08 320357 P111 F7 CONN 02 PIN MALE 320122 P112 OFT HDR STR 02PIN LKG 156CC BRKY 320114 P113 E6 CONN 4PIN MALE AMP 350211 1 320118 P114 4 CONN 02 PIN MALE 320122 P115 E6 CONN 02 PIN MALE 320122 P116 D6 HDR STR 26PIN DUAL ROW 100CC 320167 P117 F7 HDR STR 02PIN LKG 156CC BRKY 320114 P119 E7 HDR STR 04PIN LKG 156CC 320025 P120 06 02 PIN MALE 320122 P121 HDR STR 26 DUAL ROW 100CC 320167 P122 AB TERM PC MA 093 320002 P123 E7 CONN 02 PIN MALE 320122 P124 E7 CONN 02 PIN MALE 320122 P125 C4 HDR STR 02PIN LKG 156CC BRKY 320114 P126 C4 HDR STR 02PIN LKG 156CC BRKY 320114 020860 PWB ASSY Motherboard 0101 0102 R101 R102 R103 R104 R105 R106 R107 R108 R109 R110 R111 R112 R113 R114 R115 R116 R127 R128 R129 R130 R132 R133 R134 R135 R136 R137 R138 R139 R140 R141 R142 R143 R144 R145 SP101 0101 0102 0103 0104 0105 0106 0107 0108 0109 XU101 XU102 XU103 XU 104 XU105 p XU106 C XU107 XU108 XU109 21 E6 AB U101 B8 U102 B8 U103 B8 U104 A5 U105 D8 U1
36. 5 Connect the six cool detector ads to J2 being careful to see that the colors of the various leads match the board marking m UA 7 Connect the chopper wheel motor to J6 and the wheel assembly interrupters to the correct J3 and J4 connectors 8 Connect the slave cable from the cpu board to J2 on the microcontroller board Testing Procedure Turn power on If there is a noticeable power supply squeal or the i r source is not lit turn power off and troubleshoot the various input power busses Check for 15 0 vde at j7 4 15 0 vdc at j7 3 and 5 0 vde at j7 1 Check the voltage drop across r50 shouid be less than 1 8 vdc and decreasing in voltage whenever the unit is first turned on This voltage drop 15 ine amount or current the cool detector is drawing Damage may occur to the cool detector if the current is too high 2 Check that the a g c voltage at the junction of ri4 and qi e is between 9 5 vdc and 3 5 vdc Check that the filter pulses at u4 4 are approximately 1 7 ms wide and approximately 4 5 The width of these pulses vary slightly with the chopper wheel motor speed setting see figure 1 ur Assembly 020785 k CA a 10 Check that the 3 80 filter pulse at 04 2 is approximately 4 5 vpp and approximately 2 6 ms wide Adjust the pulse duration for 25 milliseconds with the chopper wheel motor adjustment potentiometer see figure 1 heck the cool detector output pulse
37. 5 at 10 55 36 500 INC Buy Items Assembly 3005686 INTOX 5000 110V KBD COM 2SOL List Component Description Price 220097 TERM PIN GND 293D 18 ZZ2AW 15 320100 HDR STR 06 FLAT 00CC 55 320102 HSG SKT CONN OZCKT 156CC XG 30 220105 HDR STR 07PIN LKG 56CC 2RKY 1 10 320114 HDR STR 02PIN LKG 56CC 55 320117 CONN 3 POS FEM AMP 1 480253 55 320118 CONN 4PIN MALE AMP 350211 1 1 40 220119 CONN 4PIN 1 480424 0 55 320122 02 PIN MALE 85 320123 CONN 02 PIN FEMALE 55 220124 03 1 10 320125 TERM CRIMP AMP P N 60619 1 30 320130 CABLE RIBBON 16COND 12 L 29 45 320134 SOCKET MINTR SPR 026 033PD 1 10 320141 SOCKET PCI 16 PIN USED 316T 2 20 220165 CONN EDGE PCB DUAL22 156 10 75 320167 HDR STR 26PIN DUAL ROW 20CC 5 50 320171 SWITCH PUSH BUT SS MOM ACT 17 90 320172 SWITCH PUSH BUT ACT 17 90 220173 COVER GREEN MCR 51 122 1 40 320174 COVER RED MCR AMLS1C 10R 1 65 320175 SOCKET IC 16 PIN DIP 30CC STR 30 320176 SOCKET IC 20 PIN DIP 30CC STR 55 320178 SCCKET IC 40 PIN DIP 60CC STR 85 320179 RCPT PANEL MOUNT 2SKT LKG 30 220180 PLUG FREE HANGING 2 PIN LKG 30 320181 SOCKET IC 14 PIN DIP 30CC STR 30 320182 SOCKET IC 8 DIP 30CC STR 30 320184 EDR STR 10PIN LKG 100CC 85 320194 CONN EDGE PCB DUAL10 156CC 9 35 320195 HDR R A 10 PIN LG 100CC 85 320209 RCPT R A FEM DB25 BD PNL MT AP 8 00 320211 SCREWLOCK CONN
38. 952 1 320211 TUBING SHRINK BLK 3 32Dx1 2LG 910771 020725 PWB ASSY Communication Test Procedure Troubleshooting Tips NOTES Revision 1 3 15 EQUIPMENT REQUIREMENTS Test Fixture 5000 0010 Test Cable P701 Test Adapter Cable 1701 e Digital Voltmeter Keithley 175 Or Equivalent Soldering Iron TESTING METHODS Preliminary Checks Setup 1 Carefully inspect the communications boards for any obvious problems such as solder bridges missing components reversed components cold soldered joints unsoldered joints etc Be especially critical of the soldering at the printer connector j2 P1 p703 and p704 will not be installed in gol board ty Verify that ul is a 1488 ic And u2 is a 1489 ic The ic s should be seated correctly in their respective sockets Verify that the following voltage input lines are not shorted to ground or to each other resistance readings may vary with different dvm s VOLTAGE LEAD GRD 15 0V 15 0V e 15 0 VDC 4 0 KO INF 4 0 15 0 VDC 3 5 3 0 MQ 15 0 VDC x5 5 KO 5 5 4 Connect the 25 pin connector from the fixture to j702 rs 232c interface the 5 pin adapter cable to j701 keyboard the test cable p701 to p701 power input cable to p702 5 Connect the digital voltmeter to the 5 0v test point positive lead and the 15 0v test point negative lead Testing Procedure 1 Connect the test fixture power cord to the 1
39. ALL CAPACITOR VALUES ARE MICROFARADS 928524 SH 3 2 REV U IF 7169 15 USED INSTEAD MPS9897 AM 180 CHANGE IN ORIENTATION IS REQUIRED UNEN INSERTING IMTO BOARD BOTTOM 1 23 0000000 o P305 22 44 NOTE FOR PCB 120 C SEE OBSOLETE DRAWING 020824 8 PCB 085 NOTE sE OLETE DRAWING 020624 8 THIS DRAWING SHOWS THE USE OF MOTOROLA 58097 ANO MPSB093 TRANSIS ACEO BY 7159 AND TiS 95 RESPECTIVELY THE FLAT SIOE MUST 0 WHEN INSTALLED cw 310120 D NOTE THIS DRAWING SHOWS THE USE OF MOTOROLA MPS6097 5 93 TRANSISTORS W REPLACED BY 71397 AND 71593 RESPECTIVELY THE FLAT SIDE MUST BE ROTATED 100 WHEN INSTALLED Bill of Materials Assembly Number 020524 Assembly Desc PWB ASSY Printer REFERENCE DESIGNATOR C301 C302 C303 C304 C305 C306 C307 C308 C309 C310 C311 CR301 CR302 CR303 CR304 CR305 CR306 CR307 E CR308 CR316 F301 F302 F303 F304 F305 F306 F307 P303 P303 P301 2 P302 Q301 Q302 Q303 Q304 Q305 Q306 Q307 Q308 Q309 Q310 Q311 Q312 Q313 Q314 Q315 Q316 020524 PWB ASSY Printer COMPONENT LOCATION COMPONENT DESCRIPTION CAP CER 01UF CKO5BX103K CAP TANT 10UF 20 35V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 5
40. AMP P N207952 1 2 50 320213 FILTER RFI CURTIS P N 1600CA03 49 25 320219 SOCKET IC 28 PIN DIP 60CC STR 55 320269 HDR STR 04PIN 156 45 320357 CONN MALE MTG 08 POS AMP 1 65 320363 RCPT FEM DIN SPOS PNL MT 5 80 320370 HDR STR 02 PIN LKG 100CC 55 120417 HDR R A O4PIN LKG 156CC 85 320441 SOCKET STRIP 30P0S 100CC 24H 3 00 320442 HDR STR 30PIN FLAT 100CC 1 95 320485 SOCKET IC 20 DIP 30CC 2 20 320486 SHUNT 02205 025LEAD SIZE L C 15 220488 CONN MTHR BD PRESSURE 60 220489 CONN PRESSURE MTHR BD 1 15 320498 SOCKET 24 PIN 22 320501 CONN O6CKT SUBMIN TERMINAL 3 55 230027 WIRE 18GA VIO WHTx18 0 L W 1z5 30 730169 18 BLK WHTx18 0 L 73 30 Page 4 LVPSRPO2 300 Assembly 000568 Component 330179 330183 320196 330292 330293 330294 230295 330296 330297 330414 330415 330445 330455 340016 340025 340026 240028 240031 240035 240048 400004 400015 400019 400025 220021 500028 401011 01132 m Printed by AULLD INC Description JUMPER PREFMD 22GA INSL 6 JUMPER PREFMD 223A INSL CORD PWR BLK P E 22120 1738 JUMPER PREFMD 22GA INSL 22C C CABLE RIBBON COND 29 5 6 CABLE ASSY DATA MP 25 08 CABLE ASSY COMM 5000 CABLE ASSY PWR MP DISPLAY S000 WIRE 18GA YELx14 2 2 L 016 WIRE 18GA BLKx9 00 L W 125 WIRE 22GA REDx6 25 L W 016 WIRE 22GA WHTx4 50 L W 016 WIRE
41. E GLASS 1 WIDE 3M 361 85 00 560018 NEATHERSTRIP 1 4x3 4 00 560015 WEATHERSTRIP 25x2 75 W PSA 1 00 200188 DIODE 1N4148 COMPUTER GRADE 15 900192 XSTR TIS93 60 200193 ASTR TIS97 85 200208 SOCKET 16 PIN DIP 45 200219 TERM CRIMP MX SSH 22 28WS REEL 226 200220 TERM CRIMP MX CH 22 30WS REEL GE 202089 HDR STR 04PIN LKG 100CC 55 302303 HOR STR D6PIN LXG 100CC 286 272309 YSG SKT CONN O6OCKT 190CC 35 Page 8 uVPSRPOZ rinted by AULLZ 4 19 95 1 55 3 500 INC Suy Items Assembly 2005586 220 120V KBD CCH Z230L uist ZSomponen Description rice 202458 STR 92 FIN FLAT 11065 202618 3SG SKT CONN OZCKT 100CC LEG Pew 522775 ZSG SKT CCNN 24CEXT 20CC L amp G 2603049 IZ LTAIZCON CUAL Lg 203361 SCR 6 32x 375 PR TLH STL EO 50346 INSULATOR XSTR TOZ23 503402 WASHER SHLDR INSUL 7S220 4STR SEX 504028 RES FILM 1 50K OHM 1 4W 1 204031 AES FILM 10 OHM 1 4W 1 39 304033 ES FILM 100K 2 4 1 23 204034 ES 10 OHM 1i 4W 1 59 204036 5 12 1 OHM i 4W 1 39 304045 RES FILM 150 1 4 1 LS 204055 RES FILM 1 0X OHM i sW is 39 304060 ES FILM 20K OHM 1 4W 1 2S 294072 RES FILM 2K OHM i 3W 1 39 304082 RES 33 2 OHM 1 4W i 30 204091 RES FILM 47 5K OHM 1 4W 1 39 294093 RES FILM 475K OHM 1 4W 1 30 904103 RES 6 81 OHM 1 4W 1 30 204105 RES FILM 61 9K OHM 1 4W 1 2 30 24111
42. ER SPDT 0117 170118 MOM 300084 SWITCH PRESSURE RANGE 310118 PWB THERMOSTAT REV D 210129 PRINTER REPL 5000 310129 PWB SWITCH FUNCTION 5000 REV C 210143 PWB MOTHER W TC 5000 REV J 310167 PWB COMM 5000VA 866 PATT E 310183 FWB PROC MULTCHNNL 5000N FAT D 310186D PWB MICRCNTRLLR 5000 568 C 310188 PWB CPU 5000 68 PATT B 310196 EWB OPTIONS 5000 68 FATT C 320002 TERM 093 220014 HDR STR O6PIN FLAT 156CC 229025 TR STR 04PIN 255 220027 ZR STR OSPIN IS6CC 220028 HSG S3KT CONN 0S5CKT 25CC XG 20030 HDR STR 03PIN LKG 156CC BRKY 220031 56 SXT CONN 155CC UNG 220041 IOCKET LAMP GILWAY P N 823 220057 LUG SOLDER KULKA SMITH 81422 5 220068 TERI ITST THSUL g1H 4 40 TG 320075 JACK FHONO PNL MT W 25D BSHG amp 220084 SDR STR 0 220085 EDR C CTDTN PLAT 22238 WwW QU wore an qm WI lt Uy O oc m ti d w U U 3 oo O Uli gt n e ur n poU tr b b gt 959 Pr 1 ts w tab ae Un O mt m m 1 4 oo O wv Ut t Ut U1 up ote dO Ul 4 PEE LVPSRPO2 Printed by AULLD 4 19 9
43. MET MT END ADJ SX 3 30 H 102039 POT CERMENT PC MT TOP ADJ i00K 3 30 103042 RES WW 10K 5W 5 1 40 253043 RES FILM 2 21K 1 49 1 33 233044 RES FILM 475 OHM 1 40 1 39 103045 RES 3 16 OHM 1 4W 1 30 103050 RES NET 10P SIP 94100K 1 8W 2 55 203060 PHOTOCELL VACTEC VTL5C2 9 10 110005 CAP CER 1UF 20 50V 30 110007 CAP TANT 68UF 25V 3 85 110011 CAP CER 001UP 50V 30 210030 CAP TANT 10UF 12 127 1 55 110031 CAP CER 30PF 50V IC 300BCROSOK 20 210032 CAP CER 20PF SPRAGUE 5 020 55 210037 010 5 103 55 110038 z2UF CK06BX224K 85 210061 CAP TANT 4 7UF 20 16V RAD 55 10093 CAP TANT 47UF 20 35V 4 95 210097 CAP CER 120PF CKO5BX121K 55 210098 CAP 2PF 50V 3 219099 CER 10PF 10 500Y 2 40 119100 CAP METAL FOLY 2UF 120V 2 40 212104 CZAP TANT 2 2UF 22V a5 21921039 TANT LOOUF 10V SCRi3CLO7 MH 2 29 2292114 229 2 05 8 222 z 210121 ELCTLT 4700UF SaV 20 AXL x D 219123 ZAP VAR 7 40PF 22 95 110128 JAP SER CIU 57 350585425 55 220012 COIL 1MH 5 16OMA i9 OHM DCR 3 50 222018 JOKE SIDE BAND 130MH2 7 22 CHM zeas uVPSRPO2 Printed by AULLD On 4 19 95 at 10 55 36 500 CMI INC Buy tems Assembly 2005685 INTOX 5000 110V KBD COM 280L List Component Description Price 220042 FMR PWR 28VCT 1 24 115 220V 27 25 220063 PAR SPLY ii10 22013 45 i15 OUT 109 90 229018 ZTAL 1 8432MHZ HC 5 U 8 5
44. OHM 1 4W 196 RES FILM 10K OHM 1 4W 1 RES FILM 100K OHM 1 4W 5 POT CERMENT PC MT TOP ADJ 100K POT CERMENT PC MT TOP ADJ 100K RES FILM 100K OHM 1 4W 5 RES FILM 12 1K OHM 1 4W 1 CMI REPLACEMENT PART NUMBER 110005 110005 110005 110005 110005 905004 230030 902303 100014 904034 100014 904034 904034 100014 102039 102039 100014 904036 Test Procedure Troubleshooting Tips U Revision 1 3 43 EQUIPMENT REQUIREMENTS Digital Voltmeter Keithley 175 Or Equivalent Option Board Test Fixture Soldering Iron Approximately 18 Of Tygon Tubing 3 32 1 0 TESTING METHODS Preliminary Checks Setups 1 ta us UA 10 Caretully inspect the option board for anv problems such as solder bridges missing components reversed components insufficient soider cold solder joints etc be especially critical around the 21 and z2 hand soldered parts Verify that no shorts occur between pi 10 15v 11 grd and p1 20 5v on the option board Insert the options board into the test fixture connector pl Connect the test fixture output connector to jl on the board Tum power on to the unit under test Check for tollowing voltage e 02 4 2 5 VDC 15 VDC 02 3 2 5 2 15 VDC e Ul 11I 5 0 VDC 2 VDC Flow Rate Option Only Adjust r18 for 2 20 vdc at u2 7 Adjust r17 for 3 20 vdc at the b test point on the fixture Readjust the setting of r18 and
45. R PLAIN STL ZN 6 110 408022 WSHR LK INT TOOTH STL ZN 8 110 408032 WSHR LK INT TOOTH STL ZN 10 10 408035 WSHR NAR PLAIN NYLON NAT 6 10 408041 WSHR NPRN 55500 16010 062 55 408044 WSHR SHLDR NYL 3120Dx 187SDx 85 408064 SCR M2 6x4 PR PHN STL ZN 10 408066 GROMMET RUBBER 15 408077 WSHR 4221Dx 8750DX 1 40 408078 WSHR ROCKFORD 8071 0138 ZINC 30 408096 WASHER FLAT 10 1 10 410064 ADAPTER 25x 25 MALE 55 410083 FITTING PLSTC 10 32x1 8 BARB 230 210084 SPRT NYL PCB 1 251 5 255 410085 SPRT NYL PCB 31HEXx 38L 6 55 410087 STDF ALUM F F 2SHEXx 88L 6 37 55 410088 ELBOW MALE P4MEB 4 85 410090 UNION 1 4 TEE P4 TUB 4 1 10 410091 FEET 3 4 IN 3M SJ5523 WHITE 225 Page 5 LVPSRPO2 Printed by AULLD On 4 19 96 at 10 55 36 600 CMI INC Buy Items Assemoly 005686 INTOX 5500 110V KBD COM 2SOL ist Component Description Price 4106092 RETAINER SOUTHCO 22 35 392 15 410093 RETAINER SOUTHCO 32 32 151 41 30 10094 SHR SOUTHCO 82046 161 41 55 419095 SPRING SOUTHCO 43 3 1 24 33 410096 STUD SOUTHCO 82 240 1 95 110097 FEY SOUTHCO P N 22 90 224 10 155 410113 COUPLING PLC 220 54 2 60 10115 FTG BRS BRBD RT FEM IND SP 3 85 410115 FTG BRS BRBD 1 4 STRAIGHT BHD 2 49 410125 FITTING BRS STR 1 4BARB 1 4NPT 2 40 1101560 ELBOW BRS 3 8 BARBx1 4 NPT 5 3 410151 FITTING BRS STR 3 8BARBx1 4NPT 1 65 410168 3 8 BARB 295 110192 FTG BRS BARBED 3
46. RENCE DESIGNATOR C1 C10 C11 C12 C13 C14 C15 C17 C18 C18 C19 C2 C20 C21 C22 C23 C24 PN C25 C26 C27 C28 C29 C3 C30 C31 C32 C58 C59 020785 PWB ASSY Analog Processor 020785 PWB ASSY Analog Processor COMPONENT LOCATION E7 E6 E6 E6 COMPONENT DESCRIPTION CAP TANT 68UF 25V CAP CER 1UF 20 50V CAP TANT 4 7UF 20 16V RAD CAP CER 1UF 20 50V CAP CER 033UF 50V CKOSBX333K CAP TANT 4 7UF 20 16V RAD CAP CER 1UF 20 50V CAP TANT 4 7UF 20 16V RAD CAP CER 1UF 20 50V CAP METAL POLY 22UF 100V CAP CER 1UF 20 50V CAP TANT 68UF 25V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP 22UF CK06BX224K CAP CER 100 PF 500V CAP CER 100 PF 500V CAP CER 1UF 20 50V CAP TANT 4 7UF 20 16V RAD CAP CER 10PF 10 500V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP METAL POLY 5 100V 027 CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 220PF CK05BX221K CAP TANT 4 7UF 20 16V RAD CAP TANT 4 7UF 20 16V RAD CAP TANT 4 7UF 20 16V RAD CAP CER 470PF 500V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP TANT 4 7UF 20 16V RAD CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP TANT 47UF 20 35V CAP TANT 4 7UF 20 16V RAD CAP TANT 4 7UF 20 16 V RAD CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP TANT 47UF 20 35V CAP TANT 4 7UF 20 16V RAD CAP TANT 47UF 20
47. STR SOCKET IC 14 PIN DIP 30CC STR SOCKET IC 14 PIN DIP 30CC STR SOCKET IC 14 PIN DIP 30CC STR SOCKET IC 14 DIP 30CC STR SOCKET IC 14 PIN DIP 30CC STR SOCKET 14 PIN DIP 30CC STR INSULATOR T0220 NUT HEX STL ZN 2 56 PWB PRINTER REPL 5000 SCR 2 56x 375 PR RDH STL ZN 100010 100010 100001 100006 100006 100006 100006 100006 100006 100006 100010 100010 100010 100010 100010 100010 100010 100010 100010 100010 100010 100010 2200898 220056 220056 220036 220036 220056 220070 220070 320178 320181 320181 320181 320181 320181 320181 320181 470085 400004 310120 401011 EQUIPMENT REQUIREMENTS Test 5000 Intoxilyzer With Tested Boards Digital Voltmeter Keithley 175 Or Equivalent Purposes Only Oscilloscope Hitachi V202 Or Equivalent Purposes Onlv X10 Scope Probe Tes Software 46 01 Printer Cards 015010 Tags And Label As Required TESTING METHODS Preliminary Checks Setup Caretully inspect the printer boards tor any obvious problems such as soider bridges missing components reversed components cold soldered joints unsoldered joints excessive flux residue around the 8255 i c Etc 13 uy 4 Verify that all i c s are the correct ones and oriented properly Carefully insert the printer boards into 101 on the mother board Connect the printer cables into p301 p302 and p303 All switches on the switch board should be in the
48. board and reading from the AtoD converter on the analog processor board A description of the functions of each digital IC and how they fit in the grand scheme of things follows The IC labeled U1 74HC245 is an octal tri stated non inverting bi directional bus transceiver The basic function of this chip is to buffer the data moving to and from the analog processor board as the DAC and the AtoD are accessed If the DAC is written to i or the AtoD is read from the transceiver is selected and told which process read or ao write is taking place All other chip accesses which cause the address data lines to always be active are prevented from reaching the analog processor board because it is susceptible to this digital noise The DIR input Pin 1 controls the direction of data and is tied to RD When the AtoD is accessed on the analog processor board RD transitions low changing the direction of data so that information can be read from the AtoD converter The input labeled G is a gate input whose signal is generated by the AND gate whose inputs are the DAC and AtoD chip selects The AND gate prevents all but the DAC and AtoD chip selects from enabling the transceiver which prevents digital noise from reaching the analog processor board at critical times The chip labeled U2 8255 is a parallel input output PIO interface IC The PIO chip serves as the communication link between the host CPU subsystem and the slave microcontrolle
49. c Or Higher Vacuum Pump Digital Thermometer Fisher Scientific Or Equivalent 4 Test Keyboard Ibm At Model Or Equivalent Cardinal Keyboard Ibm Prowriter Printer Or Equivalent Flow Rate Gauge Gilmont D7093 With Pump And Adjustable Power Supply Of 20 Volts 10 Amps Calibration Platform Preparation Preliminary Instructions 1 Verify that the intoxilyzer to be calibrated has completed the three day burn in cycle The intoxilyzer to be calibrated should have been turned on a minimum of 1 0 hours in the calibration room for stabilization purposes place the intoxilyzer on the calibration platform 2 Check that the customer software has been placed in the processor 3 filter units use 53 12 86 5 filter units 4 use 55 12 86 and cpu board If customer software is not available use the oregon software 3 Place all the appropriate covers on the intoxilyzer note connect simulator heated hose connector to the 15 volt pins on the mother board if this option is called for on the unit 4 Connect the external printer to the rear of the unit if this option is in the unit Check that a sufficient supply of paper is available to collect the printer calibration data 5 Check that ail simulators are up to temperature and sealed properly Anv questionable heating problems must be checked with the digital thermometer Any questionable air leak problems must be checked with the vacuum pump note ail tygo
50. ches 1 and 3 abaca s4 third digit on and 55 display during test on the switch board to the up position Depress the start test switch Insert the printer card when prompted by the display The unit will now do an abaca breath and calibration routine Use the 020 solution simulator for this check The printed values must be 002 of the actual solution value Repeat the above check for the missing 040 solution 002 the 080 solution 002 the 100 002 and the 150 solution 004 note all tolerances are from the actual solution value i e 099 002 Depress the esc esc again Whenever the various functions are displayed depress the c key insert a printer card and perform an aca routine with the acetone solution The test should be aborted and an interferent detected message printed out Depress esc esc again Whenever the various functions are displayed depress the d key insert a printer card and perform a diagnostics check The diagnostics for the prom ram temperature processor motor speed ee prom serial number match range stability and auto calibration should have passed printed after them A printer test of all letters of the alphabet and numbers from 0 through 9 will also be performed Depress esc esc again Depress the i key whenever the function codes are displayed Insert the printer 47 card and perform an internal standards check The readings should be internal 100 002 internal 2
51. ctor for connecting a standard IBM XT keyboard Power is provided on pins 4 and 5 of J701 to power the keyboard while pins 1 and 2 are used to clock the information serially back to the CPU board Pin 2 carries the data while pin one supplies the clock for the synchronous retrieval of the data Transistor Q1 simply acts as an inverter so that the clock signal reaches the UART in the proper state Pins 2 3 and 7 of connector J702 are the only ones currently used for asynchronous data communications Pin 2 is the data transmit line Pin 3 is the data receive line Pin 7 connects the remote instruments ground to local ground esablishing a common reference IC U2 translates the incoming RS 232 level signal to a standard 5 voit digital signal U2 has a single supply voltage of 5 volts IC U1 translates the outgoing digital signal to RS 232 levels U1 has a dual supply of 15 volts There are two unused gates one of U2 and one of UI These gates are referenced to either 5 volts or ground so they will not drift or oscillate which could lead to chip failure The connectors P703 P704 are used for spare 15 volt access points NOTES Revision 1 3 i2 Schematic NOTES Revision 1 3 13 OPTIONAL OPTIONAL P784 P783 P781 0 6 2 11 488 14 m UZ A 0814897 U1 B 1498 2 81489 U1 C U2 C 961489 RING DETECT P702 02
52. d Turn the test fixture off Discharge the 40v capacitor Remove the ac power cord from the rear of the unit Place the test label marked with the test technician s clock number vorkorder number tif known and date of the successful testing of the board near the serial aumber marking on the board Remove all cables and connectors then place the completed board in the static proof bag before any further handling is performed Mother Board Assemolv 020860 wa 45V FLOW RATE OPTION 15V GND 4 R6 10K R5 12 1K GND 3 67 M1 GND 1 1 1 4 A A16 10K 10K Li 5 818 1001 3 c5 C4 LM336225 N 4 m GA 1 4 2 5V 2 2 3 6ND NOTES UNLESS OTHERWISE SPECIFIED 1 ALL RESISTORS ARE IN OHMS 1 4W a m nrramma anf ASSY 0208536__ FEV ASSY 0208536 PWB 310196 PWB 310196 PATT C PWB ASSY OPTIONS 5000 68 020853 REV C Bill of Materials Assembly Number 020853 Assembly Desc PWB ASSY Options REFERENCE DESIGNATOR C3 C4 MAD SLM COMPONENT LOCATION COMPONENT DESCRIPTION CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V CAP CER 1UF 20 50V 2 20 IC LM336202 5 RGLTR NAT ONLY HDR STR 06PIN LKG 100CC RES FILM 100K OHM 1 4W 5 RES FILM 10K OHM 1 4W 1 RES FILM 100K OHM 1 4W 5 RES FILM 10K
53. e Check the a g c Level at the junction of r14 and ql e on the processor board The voltage should be between 3 5 vdc and 9 5 vdc The cool detector output signal at ul 6 should be approximately 7 0 vpp see tigure 1 Check the various signals levels at j1 1 to j1 20 on the microcontroller board see figure 2 Depress the reset switch If the unit has not come out of warm up mode set the cell temperature test switch to the bypass position The intoxilyzer will now perform a diagnostics check Whenever the channel signal and readings are displayed depress esc esc on the until the ch c d 5 menu is displayed Depress the key to auto range the unit Verify that channels 0 1 and read signal levels of 3500 and the last four digits that read the noise levels are less 0020 Ch 1 3500 0012 Turn power off Remove the slave cabie trom j2 Remove the microcontroller board from the processor board Remove the test software trom u 5 socket Place a test label with the technician pay number and date code on the assembly near the rev marking on the board Place the tested board a static proor bag vetore any other handling is performed Microcontroller Board Assembiv 020787G01 Chapter 6 020785 Analog Processor Board Assembly General Description The main purpose of the analog processor board assembly is to convert the signals from the cooled lead selenide IR detector i
54. e printer head should travel across the printer in a fairly smooth fashion fter the print test is completed ihe printer card should be expelled smoothly and not twist or turn greatly internal Printer Board Assembiv 020524 Inspect all printed information for compieteness and good printed quality Any problems areas will show up as missing dashes after the seven printer head driver stages q307 through q301 Tum power off Remove the three printer cables from board Do not remove the board from j101 until the 40 vde line has been discharged to less than 5 0 yde Damage can occur to the finger contacts if the 40 yde line 15 not discharged Remove the printer board trom 1101 Place a test label near 4308 Record your initials and the month vear the board passed test Place the tested board in a static proof bag container or carrier before any other handling performed Internal Printer Board Assembly 020524 Chapter 5 020787 Controller Board Assembly General Description The controller board assembly is the home of the slave microcontroller which handles all signals retrieved from the IR optical bench The functions of the controller board are toggling the sample and hold pulses used on the analog processor board communicating information retrieved from the optical bench to the host CPU subsystem maintaining calibration information which is stored on the analog processor board writing to the DAC on the analog processor
55. ed note see 6 1 for actual function mode clarification Depress the t key on the keyboard The display should now prompt the operator to enter the number of solutions that will be used to calibrate the intoxilyzer The number of solutions that will be used during calibration will normally be 5 Depress the enter retum key as necessary for the 40 80 100 and 150 solution values note all solution values entered at this time will be actual gas chromatography values recorded on the alcohol standards analysis data sheets Always enter the lowest solution to highest solution values Depress the enter return key The operator will be prompted to do an acetone check Depress the y key for yes to include acetone detection in the calibration routine Then press the enter return key to continue with the calibration routine If the customer does not want the acetone subtract feature depress the n key then press the enter return key Check with the responsible quality control personnel if any unit is questionable 2 Depress the enter return key Insert a printer card when prompted by the display The display will then prompt the operator to connect the water reference 620 solution 00 to the calibrate port All simulators must be connected to the recirculation port on the rear of the intoxilyzer Depress the start test switch The intoxilyzer will now go through eight checks of the water reference The printed result of this tes
56. epress key to do an auto range function Channels 0 1 ana 2 will now have signal levels of approx 3500 and noise readings of less than 020 Depress esc esc repeatediv again until the various function modes are displayed Depress the key enter and esc esc again Another set of various function modes a b c d e f g h i p v q will be displayed Depress the e kev preliminary test data Go through this mode operation bv repeatedly depressing the enter kev When prompted by the time and date displays enter the correct time and date information CPU Board Assembly 020833G01 Depress esc esc again Depress the b key breath Insert a printer card when prompted by the display and perform a breath test Check the printed card for the correct heading model serial number time date and breath routine results Depress esc esc again Depress the d key diagnostics Insert a printer card when prompted by the display A diagnostics test ror the prom ram temp processor motor eprom serial number match range stability auto cai status and a printer test will be performed Range stability auto cai status and diagnostics should print failed ail other tests should print passed The printer test will print all letters of the aiphabet and numbers trom 0 to 9 Depress esc esc again Depress the f key clock frequency This display should read set to 32 768 khz Check for thi
57. er 9 020853 Options Board General Description Schematic Printed Circuit Board Map BOM Testing Procedure Troubleshooting Tips Part II Final Instrument Testing Procedures Chapter 11 Final Intstrument Test Procedure Chapter 12 Instrument Calibration Procedure Revision 1 3 3 28 28 29 30 3 32 32 33 34 35 36 36 37 38 39 40 40 4 42 43 44 45 46 Part I System Circuit Descriptions Chapter 2 020867 Switch Board Assembly Chapter 3 020725 Communication Board Assembly e Chapter 4 020524 Internal Printer Board Assembly Chapter 5 020787 Controller Board Assembly e Chapter 6 020785 Analog Processor Board Assembly Chapter 7 020833 CPU Board Assembly e Chapter 8 020860 020861 Mother Board Assembly e Chapter 9 020853 Options Board Assembly e Chapter 10 020712 Remote Turn On Assembly Revision 1 3 7 32 36 40 40 Chapter 1 Introduction Join me in an adventure into the heart of one of the most technically advanced instruments serving both law enforcement and private industries The Intoxilyzer 5000 Series 68 touts some of the best specifications in the breath alcohol measurement market This manual will attempt to explain how the 1 5000 achieves these remarkable specifications Instrument operation and software specifics will not be covered in this manual in great detail This first draft of a 68 series service manual will delve mo
58. eversed components wrong components insufficient soider cold soider joints etc Pav particular attention to the proper polarity of c101 740v rectifier 4101 105 c106 108 and 125 see component layout drawing 020617 020618 sheet 2 Rotate c101 slightly to eliminate a possible capacitor case to board feed through short 1 105 5 and 6 should be shorted together eritv r137 is 20k per note 3 on the schematic Remove the cpu ram printer and mother boards trom the 5000 test trame fixture Insert only the mother board into the test trame fixture at this time Connect the pressure switch hose to the pressure switch 568 mother boards 020861 to be used with the flow rate option will not have a pressure switch Place the following connectors into their respective plugs on the mother board P107 Thermostat 108 Power Switch 109 Input P110 Power Supply P111 Cell Heater Tape 12 LR Lamp P113 40 Transformer 114 Pump P115 Simulator Solenoid P117 Reset Switch Check that no shorts are present between the 5 0 15 0v 15 0v and 40 0v lines and ground The 5 0v fuse should read approximately 5 ohm to ground the 40 0v fuse approximately 10 k ohm after ci QI is charged up bleeder resistor r142 in board Verify that the 5 0v fuse is 7 amps 15 0 fuse is 2 amps the 15 0v fuse is 5 amps and the 40 0v fuse is 7 amps Connect the te
59. fore determines which peripheral chip is being accessed by the microcontroller The addresses of each of the peripheral chips are set in hardware The software programmer knows where each of the peripheral chips are located from this hardware decoding scheme and writes programs accordingly The AND gate driving the G2A pin on U6 serves to disable all peripherals when RD and WR are inactive This occurs frequently as the microcontroller accesses program memory stored in the eprom The chip labeled U8 74HC08 is a quad AND gate chip Two of the four gates are used in this circuit with the inputs of the other two gates tied to ground to prevent oscillation The function of the two AND gates used is described in the chip description which utilizes the gate The explanation will not be repeated here The chip labeled U9 74HC04 is a hex inverter chip Only one of the six gates are used in this circuit with the inputs of the other five gates tied to ground to prevent oscillation The single inverter utilized is used to invert the signal generated by the parallel communication to a signal compatible with the 8051 s external interrupt input Revision 1 3 24 m 7 g um enumenar EEE 8 82 33 gt gt 7 E 5 A m ic ta a
60. he wavelengths of interest to pass through to the cooled detector The signal is then converted by the analog processor to a digital signal which is then converted to an alcohol concentration by the digital processor The standard sample sequence begins by establishing a zero point reference The zero reference is obtained by measuring the amount of infrared energy reaching the detector while the sample chamber is filled with ambient air During sample introduction the amount of infrared energy reaching the detector falis as the alcohol in the sample Revision 1 3 4 chamber absorbs part of the infrared energy The difference between the amount of intrared energy measured during zero reference and the amount measured during sample introduction is translated by the instrument into breath alcohol concentration To assure accurate test results the Intoxilyzer 5000 is able to detect other common substances known as interferents which have similar absorption wavelengths to alcohol The intertering substances are either compensated for or reported in the final test result About This Manual The Intoxilyzer 5000 Series 68 Service Manual explains the inner workings of a 68 series Intoxilyzer 5000 This manual includes circuit schematics circuit descriptions several block diagrams circuit board maps with associated bills of materials testing instructions and troubleshooting tips This manual will be the ultimate guide to the inner work
61. ings of the Intoxilyzer 5000 Series 68 Terms and Conventions This service manual will use certain terms and conventions to refer to specific signals chips and other items Although many of these conventions may seem intuitive a brief list of terms and assumptions is listed in this section for reference If this section seems to occupy most of your attention a call to the CMI service department may be in order These are some general assumptions When Intoxilyzer 5000 or instrument is referred to in this manual the instrument referred to is the Intoxilyzer 5000 68 Series This manual covers both the Gas and Remote Turn On options These are some general conventions All integrated circuits will be referred to as IC s All IC s will be referred to by either reference designator or chip function Each circuit assembly will be contained in a separate chapter A Printed Circuit Board Map details the locations of the components on the board Revision 1 3 3 Contacting Customer Service Customer service for CMI can be reached voice at the following telephone numbers or by mail at the following address CMI Customer Service Department 316 East 9th Street Owensboro KY 42303 TX 1 800 835 0690 FX 1 502 685 6288 If the problem regards instrument failure or similar problems ask for a technical service representative NOTES Revision 1 3 6 Chapter 2 020867 Functio
62. inter Board Assembly General Description The internal printer board will be described in sections in an effort to eliminate confusion and to allow concentration only on the effected components Again unused gate inputs are tied to ground to prevent oscillation Digital Communication The heart of the digital section is the 8255 parallel input output PIO IC The 8255 connects to the mother board through a 44 pin edge connector P305 The arrangement of chip select CS write WR read RD reset RST and the data lines DO D7 are typical of a chip that is connected directly to the system address data bus The 8255 occupies an address whose base is determined by the hardware of the CPU subsystem The base address when accessed by the CPU causes the CS line to be taken low The latched address lines of 9 and A1 Pin10 determine which port of the PIO is accessed by the request CS from the processor The combination of AO and Al produce for distinct addresses that the CPU can access to either read or write data Three of the addresses are for the three ports Port A Port B and Port C of the PIO while the forth address is for chip configuration The chip configuration byte determines whether a port is used as inputs or outputs or both in the case of port C The configuration used in the printer board assembly is Ports A and B configured as outputs and Port C configured as half inputs and half outputs Reset is toggled from high to lo
63. n tubing from the vapor output port of the simulators is kept very short approximately 2 to minimize the effect of condensation on the readings 6 Verify that the temperature in the calibration room is between 71 f and 75 f before proceeding with the calibration routine System checks da Connect the ac power cord to the rear power receptacle Be very careful that the ac power source is correct for the unit being calibrated 110 vac or 220 vac Revision 1 3 46 8 Tum power The display should indicate a not ready mode then go into a warm up period mode of operation Do not reset the unit at this time 9 After approximately 10 to 15 minutes the intoxilyzer will come out of the warm up mode and perform a diagnostic check This may vary with customer software but would normaily consist of the following 3 prom check b ram check c temperature check d processor check e software version f internal standards only checked if intoxilyzer was calibrated previously g printer test only checked if intoxilyzer was calibrated previously h processor check processor 7 8 9 a will all show fail 10 The intoxilyzer display will then indicate the various channel signal and noise readings Uncalibrated units will normally read signal levels of 4095 0000 and noiseof 000 Calibration l Depress esc esc again until the various menu functions ch c d q are display
64. nal Switch Board Assembly General Description The switch board assembly is fairly simple and straight forward in both its functionality and design The switches serve three main functions data entry for both time and date when a keyboard is not available type of test selection i e breath calibration check custom etc and test characteristics selection i e three digits displayed print inhibit etc The board consists of five individual slide switches and one DIP style switch that contains eight separate switches These switches serve different purposes depending on instrument features and software The slide switches switch to either 5 volts or ground depending on the switch while the DIP switches switch only to ground The resistors on the board are used for pull ups on the switches that connect to ground The switch outputs and the pull up resistors are located off board NOTES Revision 1 3 8 Schematic NOTES Revision 1 3 9 2 lt e TME SET 4 CONST UPDATE 5 te DISPLAY vco TI A aio lt lt 6 9 lt GROUND lt NCREMENT NO S DATE SET PRINT INHIBIT SIMULATOR ATTENUATOR 20 CALIBRATOR OPTION mI zu 96607 CAGE MO Owe 2 on 33173 020867 A Bene wa enon ewe 1 J lo Ee e Ne ne ee
65. nication chips The 8051 maintains the operations of the optical bench while waiting for information requests from the host processor Ports 0 and 2 of the 8051 comprise the eternal address data bus Port 1 handles the sample and hold pulses sent to the analog processor board as well as the transmission of calibration data which is stored in the analog processor boards eeprom Port 3 is the special functions port from which both read RD and write WR originate Port 3 also handles incoming interrupts from either the PIO or the analog processor board Other chip inputs consist of crystal inputs for a 12 Mhz crystal and a reset line used to reset the chip on power up The chip labeled U4 74HC373 is an octal tri stated non inverting transparent latch The 8051 architecture requires Port 0 to be shared between the bottom 8 address bits and the data bus For accessing peripheral chips to work the address of the peripheral chip must be maintained while the data is either being read from or written to the chip The upper address lines are held constant by Port 2 which is dedicated to the task of addressing The lower address lines however must be latched without interrupting data which is to be read into or written from Port 0 The transparent latch U4 accomplishes this task The chip labeled U5 27c512 is a 64K byte eprom which may be erased with ultraviolet light of sufficient intensity The eprom chip stores the program which the 8051 executes The
66. nto a digital format which can be read by the controller assembly All support functions cooler control circuitry regulators eeprom etc required to meet this end are also handled by the analog processor board the description of the analog processor board will be broken up into sections or functional blocks before a big picture description will be attempted NOTES Revision 1 3 28 Schematic Revision 1 3 29 400K 6 cs f ut 4 wert 8 oo ow 2388388 ee FILTER 3 8 1 DENO Pi we Si pu m N C1 0114 0640 00 43 SERIAL EEPROM E 8 DEND PWB 3101830 PWB ASSY PROCES 020785 REV F t Bk 5 1 1 c h Q 71 zl 9 gi z i Hg b a ast 6 Wis p 5 2 73 itt L Ep Ee EN EAS Ht di E Dn 228 FES 5 m 5 5 EET E A 17 e 08 2777 9687020 ASSY TO m e i R48 gt w 07524 Sb w MAX172 T 4 C49 8 E m 5 NO PWB 310183 PATT 0 PWB ASSY PROCESSOR 5000 310183 REV F Bill of Materials Assembiy Number 020785 Assembly Desc PWB ASSY Analog Processor REFE
67. om the 568 test unit chassispiace a test label with the technician pay number and date code on the assembly near the rev marking on the board Place the tested board in a static proof bag before any other handling is pertormed issembiv 020785 Chapter 7 CPU Board Assembly Revision 1 3 32 22 44 R40 U15 8 O ra Uie TPs 777 7446154 4 244 4 ID OOC D OO HCO4 4 TP12 C TPIS TP46 TP47 TP48 TT ASSY 0208336 1 u 43256 1 270256 1 4864 1 23 TP5 O 7 U13 1 a m Ei 015 EN r2 U12 Xp Waves 18 749154 d em qe 244 7 MM58274C lt ao q gt CRS HCO4 4 Le ARM Ted C2 1215 200090 TP18 CQ ur e C4 P 017 A ADC amp u 0 014 8255A 78440 C16 ncc ES ucc D Bosw del Wow ERE 22 aU O Ax CPU ASSY 0208336 PWB TP31 SKT 8051 lt SKT 8051 lt 27 256 ar m a e 3274C gt E MAX695 4 E Y1 C4 7 US 1 c ADC1001 4 Aid U10 1 Th ml PWB 310188 ASSY CPU 5000 020833 REV D Bill of Materials Assembly Number 020833 Assembly Desc
68. r located in this assembly The arrangement of chip select CS write WR read RD reset RST and the data lines D D7 are typical of a chip that is connected directly to the system address data bus The 8255 occupies an address whose base is determined by the hardware of the CPU subsystem The base address when accessed by the CPU causes the CS line to be taken low The latched address lines of 9 and 1 10 determine which port of the PIO is accessed by the request CS from the processor The combinations of AO and A1 produce four distinct addresses that the CPU can access to either read or write data Three of the addresses are for the three ports Port A Port B and Port C of the PIO while the forth address is for chip configuration The chip configuration byte determines whether a port is used as inputs or outputs or both in the case of port C In this configuration port A is used to Revision 1 3 22 communicate byte information to the host CPU Port C is used as flow control for the bytes either transmitted or received through port A Reset is toggied from high to low in power on conditions to reset the outputs of the ports to default states The chip labeled U3 8051AH is an 8 bit microcontroller more commonly known throughout this manual as the slave processor The 8051 provides the brains for all functions of the optical bench The 805175 subsystem consists of separate ROM and RAM chips as well as commu
69. re into circuit explanation schematic diagrams bills of materials block diagrams and troubleshooting tips The assumption being that the service technician using this manual will be and should be well versed in instrument operation Now without further adieu let us be on our way General Description Depending on their physical size and structure molecules absorb light energy of specific frequencies or wavelengths The Intoxilyzer 5000 capitalizes on this physical phenomenon by measuring the amount of light energy absorbed by alcohol molecules at specific infrared wavelengths The Intoxilyzer 5000 then converts this absorption measurement to an equivalent breath alcohol concentration The result is a highly accurate non invasive means of testing a persons breath alcohol The heart of the Intoxilyzer 5000 is its optical bench The optical bench consists of a sample chamber quartz iodide infrared source cooled lead selenide detector and separate analog and digital processors to translate the signals into meaningful data The infrared source is located at one end of the sample chamber while the cooled detector is located at the opposite end The infrared energy is collimated by a fresnel lens and directed through the sample chamber The opposite end of the sample chamber uses a similar fresnel lens to re focus the collimated light through narrow band infrared filters onto the cooled detector The narrow band infrared filters allow only t
70. s at ui 3 The signal output should be between 3 vpp to 6 vpp This signal level will vary with cool detectors Check ith the test supervisor if this output signal is not within the range of 3 vpp for disposition on its use The signal output at ul 6 should be approximately 7 0 vpp The signal shouid not be jumpy or appear to be riding on a c level if this occurs roubleshoot the a g c circuit The positive peaks must not be clipped see figure 2 Check for the various signais leveis at 11 1 to 1 20 on the microcontrolier board see figure 3 Recheck that the voltage drop across r50 does not exceed 1 8 Depress the reset switch After the intoxtivzer has come out or the warm up mode of operation diagnostics check will be performed Whenever the channei signal and noise readings are displayed channeis 0 1 2 5 4 perform the esc esc function on tne keyboard Depress the whenever the ch d i menu is displayed An auto range function will now be performed on the unit Verify that the O 1 and 2 channel signal and noise levels are acceptable The signal levels should be approximately counts and the noise leveis must be less than 0020 example ch 0 3500 0015 Turn power otf Remove ail connectors placed on the processor board earlier Remove the heat sink from q6 Remove the six cool detector wires from 12 Remove the microcontroller board trom jl Remove the processor board fr
71. s frequency at u4 13 with the oscilloscope There should be a square wave of 4 5 vpp to 5 0 vpp presentthe trequency will be set at unit test The start button must be depressed to get out of the frequency set mode of operation Turn power off Check that the battery is reading 3 6 vde check that there is clock frequency pulses at 04 14 Remove ail connectors added to the board during test Remove the cpu board trom the mother board edge connector Remove the test eprom from 02 Place a test label near the 3 4 area on the board Record your initials and the month and year the board passed test Place the tested board in a static proof bag before any other handling is performed CPU Board Assembly 20833601 DISPLAY Amani Ed Lop LET LI RER rmm 28 E z A SEN 5 6 20 ree ela P illi v s10 HE 144444444 19 84810 v s o INS BEE 5 899 SWITCH BOARD CPU MO m LE ole ele olala 1 MURS RR 2129338238838 8 5 332321328 5 Exc 8 pess 5 58 Eg tep n0 ag 00 08 15 5 PWE 5 8 3181111
72. splayed Depress the start test switch again The month display should be tlashing on and off Switch 512 up and down as Mother Board Assembiv 020860 ws necessary to verify that the month can be set properly Depress the start test switch again The day dispiay shouid be flashing on and orf Operate 512 again and verify that the day can be properly set Depress the start switch again The vear display should be flashing on and off Verify that the correct vear can be set by turning 514 and 15 Depress the start test switch again Once the time is dispiayed deoress the start test switch again The minutes display should be lashing on and off Repeat the operation of 512 to verify that the minutes be properly set Depress the start test switch again The hours display should be flashing on and off Repeat operation 12 to verify that the hours be properiv set Depress the start test switch again rie display will now for a printer card to be inserted into tne card slot inspect the the time and date that was set in steps 5 2 7 and 5 2 8 after the card is expelled from the printer Verify the normal alpha numeric printout is correct tor test software 29 07 After the print test is completed the dispiay should go to keyboard Depress the start test switch The battery ram test should now be displayed After the ram board has counted down to 01 commtest will be displaye
73. st fixture bleeder resistor clip lead to the positive side of c101 Verify that the 40 0v discharge switch on the fixture is in the open position Adjust the rfi detector potentiometer ri 35 maximum counter clockwise Connect the ac power cord to the rear ot the test intoxilyzer Testing Procedure Tum power on The i r Lamp shouid be tit Check for the proper voltages at the appropriate iuses The dc voltages shouid be 5 0v x 3 13 0v 3 0 15 0v 3 0 40 6 0 Ac line Mother Board Assemblv 020860 2 voitages shouid be present at pt l 1 2 cell heater tape and p120 1 fan Verify that the ac ine voltage is present at pi 11 1 left side when 140 temperature set potentiometer is adjusted fully counter clockwise Adjust 40 clockwise until the ac voltage disappears at 11 1 note there will be a slight warm up necessary on the first board being tested due to the cell not being up to temperature Adjust ri40 just slightly beyond the point where vou lose ac at pl 1 1 1 approximately 439 from the 12 00 position Turn power orf Discharge remaining voltage on c101 bv closing the discharge switch on the test fixture momentarily Install the test cpu printer and ram boards into their respective connectors on the mother board Plug in the following interconnecting cables to the mother board P103 Start Test Switch P105 Dispiav Power P106 Processor Board P116 Display Module
74. switch repeatedly while verifying each of the various test functions Audio a beep tone should cycle on and off every second b Pump operation the pump should on and off every second olenoidipump the simulator soienoid should cvcle on and orf every second the pump willrun continuously j Blank position no test tunction Mother Board Assemblv 020860 Status the dispiay will consist of ones and zeros denoting the on or off states of the various svstem checks Do not depress th witch asal til the following status checks are made The display should be 1001110 0000 E The first status bit checks the ceil thermostat p107 15 jumpered to always show this function as being up to temperature IL The second status bit checks i rfi is present Turn r135 clockwise until the bit reads 17 Turn 55 slowly counter clockwise until the bit reads 0 then keep adjust the potentiometer counter clockwise another 1 2 turns Place ihe police 2 vay radio near the front of the fixture and depress the transmit switch The status bit should go toa Call out rfi when performing this check so that other technicians are aware of the presence of rfi in the area Turn otf the police radio ill ine third status bit checks the ciosing of the pressure switch No check will be made on this bit due to the flow rate option for the board IV fourth status bit indicates power is on and the reset s
75. t will be performed with the external printer option installed This data will be stored for the internal printer version until enough data is collected to print a full card of information If the data being printed fills a printer card the card line limit message will be displayed The display will then read press start to continue Insert a new card when prompted by the display Remove the reference solution simulator and attach the 020 solution simulator to the cal and recirculation ports when prompted by the display Depress the start test switch to initiate the calibration routine Repeat the same sequence for the 040 080 100 and 150 solution values Remove and insert new printer cards when prompted by the display After all solution values have been completed in the calibration cycle the curve fit data wiil be printed out 4 When prompted by the display to attach reference perform another water reference h5o 00 routine then the acetone routine in the same manner as the earlier solutions were performed After the acetone routine is Revision 1 3 47 un 11 12 completed a printer copy indicating the successful checking of the acetone subtract for channels and 2 will be generated Review the data for any unusual readings The acetone constant must be higher than 1 000000 After all calibration data has been successfully stored in the ee prom perform an auto cal data printout bv depressing the start
76. w in power on conditions to reset the outputs of the ports to default states Speaker Driver The speaker driver circuit is located directly beneath the 8255 in most versions of the internal printer board schematic Two main circuit paths are distinguishable by tracing the lines from Port C of the 8255 to the separate transistors Q316 and Q318 8255 Port C bit 7 PC7 is used to turn the speakeron or off This feat is accomplished by sending a digital high or low signal from PC7 to transistor Q316 which is used as a level shifter IC U306 is a hex inverter powered by 15 volts and requires logic levels of 15 volts and ground to change the level of the corresponding output The input to U306 an inverter IC is switched to either 15 volts or ground depending on the signal from PC7 Resistor R356 acts as a pull up to 15 volts for the input of U306 The inverter drives a diode resistor and capacitor network which in turn drives transistor Q319 which connects one side of the speaker on the mother board assembly to ground The diode resistor and capacitor network provides a ramping of digital output which accounts for the soft attack of the speaker chime The network prevents the speaker from snapping on and off The second circuit path starts at PC6 which is connected to Revision 1 3 16 Q318 which is used as a level shifter The output of the inverter drives a FET which changes the frequency of the tone generator The tone generator
77. witch is off No test is made to verirv this Function v The h status is a check on the acetone circuitry No test is made to verify this tunction VI The sixth status bit is a check on the printer margin setting Move the roller bar slightlv until the cherrv switch is disengaged The status bit should change from a 1 toa 70 Move the roller bar back to engage the cherry switch The seventh status bit is a check on the printer card insertion Insert a printer card into the back side of the card slot unti the reflective optical sensor path is interrupted The status bit should change from a 0 toa 1 Remove the card VIII The last four status bits wiil denote the serial number of the completed intoxilyzer unit These digits should always be 0000 on a new untested board 6 Depress the start test switch again The display should show the position of all the switches on the switch board With all the switches down the display should show 0000000x 11100 00 The switches trom lett to right are 51 to 515 The last two switches set the year The switch functions are S1 S3 Cms Mode 54 Third Digit Disabie e S5 Display The Breath Test Cycle 56 Sampie Capture 57 Internal Standards 8 Not Used i Options 9 Aca Mode 10 Set Time SH Set Date SI2 Increment Clock Numbers 513 Print inhibit 14 15 Year Setting 7 Depress the start test switch The date shouid be di

Intoxilyzer 5000 Service Manual (68 series

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