DOD Technologies ChemLogic CL96 User manual

ChemLogic®CL96
96-Point Continuous Gas Detector
Operating Manual

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ChemLogic® CL96 Operating Manual
DOD Technologies, Inc.
675 Industrial Drive Bldg. A.
Cary, IL 60013
[e-mail]
Phone [phone] • Fax [phone]
DODtec.com

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ChemLogic® CL96 Operating Manual
Table of Contents
Chapter 1 – Overview..................................................................................................................................................................... 7
1.1 Introduction ........................................................................................................................................................................ 7
1.2 Theory of Operation .............................................................................................................................................................. 7
1.3 Sampling and Monitoring ..................................................................................................................................................... 8
1.3.1 Flow Connections .............................................................................................................................................................. 8
1.4 Electrical Connections .......................................................................................................................................................... 8
Chapter 2 – Features ..................................................................................................................................................................... 9
2.1 External Layout & Dimensions.............................................................................................................................................. 9
2.1.1 Status Lamp (OPTIONAL)................................................................................................................................................ 10
2.1.2 Output Wiring Knockouts................................................................................................................................................. 10
2.1.3 Touch Screen Display ...................................................................................................................................................... 10
2.1.4 Keyed Service Door Access............................................................................................................................................. 10
2.1.5 A/C Power & Switch......................................................................................................................................................... 10
2.1.6 Flow Adjustment .............................................................................................................................................................. 10
2.1.7 ChemLogic Cassette Paper Tape ................................................................................................................................... 10
2.1.8 Maintenance Door............................................................................................................................................................ 10
2.1.9 Take-up Reel..................................................................................................................................................................... 11
2.1.10 Tubing Connections....................................................................................................................................................... 11
2.2 Maintenance Area ............................................................................................................................................................... 11
2.3 Internal Layout – Service Area ........................................................................................................................................... 12
2.4 Password Security .............................................................................................................................................................. 12
2.5 USB Storage......................................................................................................................................................................... 13
Chapter 3 – Installation ............................................................................................................................................................... 14
3.1 Selecting a Location ........................................................................................................................................................... 14
3.2 Unloading / Loading & Installation..................................................................................................................................... 14
3.3 Sample Tubing .................................................................................................................................................................... 15
3.3.1 End-of-Line Particulate Filters ......................................................................................................................................... 15
3.4 Exhaust Tubing.................................................................................................................................................................... 15
3.5 A/C Power............................................................................................................................................................................ 15
3.6 Output Wiring....................................................................................................................................................................... 16
3.6.1 Standard Output Wiring ................................................................................................................................................... 16
Chapter 4 – Setup & Configuration ............................................................................................................................................. 17
4.1 Set System Date and Time ................................................................................................................................................. 17
4.2 Gas Selection....................................................................................................................................................................... 17
4.3 Alarm Settings..................................................................................................................................................................... 17
4.4 Output Contacts .................................................................................................................................................................. 17

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ChemLogic® CL96 Operating Manual
4.5 Concentration Logging ....................................................................................................................................................... 17
4.6 Install New Tape.................................................................................................................................................................. 18
4.7 USB Storage......................................................................................................................................................................... 18
4.8 Setup Complete................................................................................................................................................................... 18
Chapter 5 General Machine Operation........................................................................................................................................ 19
5.1 Introduction ......................................................................................................................................................................... 19
5.2 General Screen Navigation ................................................................................................................................................. 19
5.3 Initialization ......................................................................................................................................................................... 21
Chapter 6 The Main Menu ........................................................................................................................................................... 22
6.1 Main Menu........................................................................................................................................................................... 22
6.1.a Analysis ............................................................................................................................................................................ 22
6.1.a.2 Point Trend Detail ......................................................................................................................................................... 24
6.1.b Load Tape......................................................................................................................................................................... 25
6.1.c Faults/Events ................................................................................................................................................................... 26
6.1.d History .............................................................................................................................................................................. 27
6.1.d.1 History -> Concentration Log ....................................................................................................................................... 27
6.1.d.2 History -> Faults/Events ............................................................................................................................................... 28
6.1.d.3 History -> TWA .............................................................................................................................................................. 29
6.1.d.4 History -> Storage ......................................................................................................................................................... 30
6.1.d.5 History -> Transfer ........................................................................................................................................................ 30
6.1.e. Help.................................................................................................................................................................................. 31
6.1.e.1 Help -> Manual .............................................................................................................................................................. 31
6.1.e.2 Help -> Diagrams........................................................................................................................................................... 32
6.1.e.3 Help -> Contact DOD ..................................................................................................................................................... 32
6.1.e.4 Help -> Configuration.................................................................................................................................................... 33
6.1.e.5 Help -> About................................................................................................................................................................. 34
6.1.f Setup.................................................................................................................................................................................. 34
6.2 Setup Sub-Menu .................................................................................................................................................................. 34
6.2.a Setup -> Point Setup......................................................................................................................................................... 35
6.2.b Setup -Adjust Flow ........................................................................................................................................................... 36
6.2.C Setup -> Outputs .............................................................................................................................................................. 38
6.2.c.1 Setup -> Outputs -> Alarms........................................................................................................................................... 38
6.2.c.2 Setup -> Outputs -> Point Alarms................................................................................................................................. 39
6.2.c.3 Setup -> Outputs -> 4-20mA ......................................................................................................................................... 40
6.2.c.4 Setup -> Outputs -> Comm Data................................................................................................................................... 40
6.2.c.5 Setup -> Outputs -> Optic Test ..................................................................................................................................... 41
6.2.d Setup -> Configure ........................................................................................................................................................... 42
Logging Configuration .............................................................................................................................................................. 42

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ChemLogic® CL96 Operating Manual
Idle Timeout............................................................................................................................................................................... 43
Output Contact .......................................................................................................................................................................... 43
Flow Fault Filter ......................................................................................................................................................................... 43
6.2.e Setup -> Date Time........................................................................................................................................................... 44
6.2.f Setup-> Passwords ........................................................................................................................................................... 44
6.3 Factory Setup Sub-Menu .................................................................................................................................................... 45
6.3.a Setup -> Factory -> System.............................................................................................................................................. 46
6.3.b Setup -> Factory -> Multi Pt ............................................................................................................................................. 47
6.3.c Setup -> Factory -> Simulation......................................................................................................................................... 48
6.3.d Setup -> Factory -> Configuration ................................................................................................................................... 49
6.3.e Setup -> Factory -> Settings............................................................................................................................................. 50
6.3.e.1 Minimum Visible Stain.................................................................................................................................................. 51
6.3.e.2 Dual Pump Option ......................................................................................................................................................... 53
6.3.e.3 Parallel Sampling .......................................................................................................................................................... 56
6.3.e.3.1 Parallel Sampling Transport Times .......................................................................................................................... 57
6.3.e.4 Reference Validation Fault ........................................................................................................................................... 57
6.3.f Setup -> Factory -> Restore .............................................................................................................................................. 58
6.3.g Setup -> Factory -> Update .............................................................................................................................................. 58
Chapter 7 – Maintenance and Disposal...................................................................................................................................... 59
7.1 Returning to a Safe State (Post-Service) ........................................................................................................................... 59
7.2 Maintenance Door Access ................................................................................................................................................. 59
7.3 Control Panel Door.............................................................................................................................................................. 59
7.4 ChemLogic®Cassette......................................................................................................................................................... 60
7.5 ChemLogic Cassette Installation ....................................................................................................................................... 60
7.6 End of line particular filters ................................................................................................................................................ 61
7.7 Flow Adjustment ................................................................................................................................................................. 62
7.8 USB Storage Drive Replacement ........................................................................................................................................ 62
7.6 Fuse Replacement .............................................................................................................................................................. 62
7.7 Equipment Disposal ............................................................................................................................................................ 62
Chapter 8 – Service & Support .................................................................................................................................................... 63
Appendix A – Parts & Accessories.............................................................................................................................................. 64
Appendix B – I/O Connection Detail............................................................................................................................................ 65
B.1 EK1101 Coupler .................................................................................................................................................................. 65
B.2 Standard Output Module (24 V Sinking)............................................................................................................................ 66
B.3 Optional Output Relays ....................................................................................................................................................... 67
B.4 Optional 4-20 Outputs......................................................................................................................................................... 68
Appendix C – System Specifications.......................................................................................................................................... 69
The CL96 is designed for safe use under the following conditions....................................................................................... 69

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ChemLogic® CL96 Operating Manual
CL96 System Specification....................................................................................................................................................... 69
Appendix D – System Event Message ........................................................................................................................................ 70
Appendix E – LDL List.................................................................................................................................................................. 71
Appendix F – Hard Wire Connection (Optional) ......................................................................................................................... 74
Appendix G – Optional Secondary Enclosures........................................................................................................................... 75
G.1 Mounting A Secondary Enclosure ..................................................................................................................................... 75
G.1.1 Remote Secondary Enclosure Mounting........................................................................................................................ 75
G.1.2 Direct mounting on the CL96.......................................................................................................................................... 75
G.2 Connecting A/C Power to the Secondary Enclosure ........................................................................................................ 76
G.2.1 Installing the liquid tight cord grip (DOD Part #2-9400-523) ........................................................................................ 76
G.2.2 Installing the A/C Power Cable....................................................................................................................................... 77
G.2.3 Attaching the A/C Power inside the cabinet.................................................................................................................. 77
G.3 Connecting to the CL96...................................................................................................................................................... 78
G.3.1 Connecting to the CL96 with Ethernet Cable ................................................................................................................. 78
G.4 Wiring Output Modules....................................................................................................................................................... 79
G.4.1 Analog (4-20 ma) Output Wiring ..................................................................................................................................... 79
G.4.2 Beckhoff Form A Relays.................................................................................................................................................. 79
G.4.3 Form C Relay Wiring ........................................................................................................................................................ 79
Appendix H – Data Communication............................................................................................................................................ 81
H.1 – Ethernet/IP....................................................................................................................................................................... 81
H.1.1 Data Format ..................................................................................................................................................................... 81
H.2 – Profibus ........................................................................................................................................................................... 83
H.2.1 Data Format ..................................................................................................................................................................... 84
Appendix I – Unified Exhaust Option Installation....................................................................................................................... 85

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ChemLogic® CL96 Operating Manual
Chapter 1 – Overview
1.1 Introduction
DOD Technologies’ ChemLogic®CL96 simultaneously monitors up to ninety-six locations (also called points)
for toxic and corrosive gases. It responds to gases that exceed a programmed alarm level by:
• Triggering visual alarms that warn of high or low concentrations
• Triggering relays or activating analog outputs to external devices
• Displaying the point number, gas type, and gas concentration
• Recording the alarm information and storing it in memory
The CL96 triggers outputs for each individual point for two levels of gas concentrations. These programmable
limits are factory-set at 1 TLV and 2 TLV for their respective gases. Each sample point may be positioned up to
400 feet (121 m) from the instrument. This allows operators to remotely monitor gas concentrations in areas
subject to potential gas leaks. The CL96 can monitor and detect a wide range of gases. It is designed for
continuous and prolonged operation when routine maintenance is performed (per factory specifications). The
CL96 employs DOD Technologies’ ChemLogic colorimetric technology, utilizing ChemLogic cassettes with
chemically infused tape for fast and accurate gas detection.
See Section 7.7 for important disposal information.
WARNING : If the system is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.
1.2 Theory of Operation
The system draws sample flow simultaneously from all installed points. Part of the sample flow is diverted
across the ChemLogic cassette tape. The CL96 uses an advanced optical detection system to measure the
light level reflected from the tape. As the target gas is detected, the color of the tape changes. This color
change results in a loss of reflected light across the tape. This loss of reflected light is detected by the
advanced optics system. The CL96 will then report a gas concentration reading and/or a gas alarm.

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ChemLogic® CL96 Operating Manual
1.3 Sampling and Monitoring
The system draws sample flow simultaneously from all installed points. Part of the sample flow is diverted
across the ChemLogic tape where it is analyzed. Each 16-point analyzer exhausts through a single port.
1.3.1 Flow Connections
Flow connections consist of “quick-connect” ports on the top and side of the CL96 unit. There are ninety-six
inlets, one for each monitored point, and 12 exhaust outlets, one for each analyzer.
1.4 Electrical Connections
“Knockout panels” for external electrical connections are provided on the right side of the CL96.

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ChemLogic® CL96 Operating Manual
Chapter 2 – Features
2.1 External Layout & Dimensions
Flow Adjustment & Sample tubing ports
Touch Screen – 19”
Wiring Knockouts
Keyed Door Access
A/C Power Switch

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ChemLogic® CL96 Operating Manual
2.1.1 Status Lamp (OPTIONAL)
The optional status lamp consists of 4 colored lights – Red, Orange, Blue, and Green along with an audible
alarm. See Appendix A for ordering information.
2.1.2 Output Wiring Knockouts
Knockouts for output wiring are located on the right-side panel near the top.
2.1.3 Touch Screen Display
The CL96 uses a full color 19-inch touch panel LCD display. All menus and data entry are accomplished by
touching the appropriate area of the screen – see Chapter 5 “Basic Operation”.
2.1.4 Keyed Service Door Access
The door uses a key lock to restrict internal access. See section 2.3 for detailed information on the service
area.
2.1.5 A/C Power & Switch
A/C power is connected on the right-side panel with a standard cable. The on/off power switch is located
adjacent to the power cable connection.
2.1.6 Flow Adjustment
Flow adjustments for all installed points are located on the top of the device. Refer to section 5.2.4 regarding
flow adjustment.
2.1.7 ChemLogic Cassette Paper Tape
ChemLogic paper tapes are accessed by opening the maintenance door. Refer to section 6.3 regarding tape
installation/replacement.
2.1.8 Maintenance Door
The maintenance door allows easy access to the ChemLogic tape for installation and replacement.
IMPORTANT : The maintenance door should remain closed and latched except when changing
the ChemLogic cassette tape. Do not open the door while in Analysis Mode.