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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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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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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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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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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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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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.

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2.1.9 Take-up Reel
Empty take-up reels are inserted at the time of ChemLogic tape installation (see section 6.3). During
installation, the previous take-up reel which is full is removed from CL96 and discarded. The previous
ChemLogic tape reel which is now empty should then be used as the next take-up reel.
2.1.10 Tubing Connections
Sample tubing and exhaust use a quick connection system for simple installation. The sampling connections
are made on the top of the CL96 while the exhaust tubing connects on the right side. See section 3.3 for
information on connecting the sample and exhaust tubing. See also Appendix C for important information on
transport times for gas from sampling point to the CL96.
2.2 Maintenance Area
The maintenance area allows easy access for changing ChemLogic tape in the CL96. Figure 2.2 shows the
internal layout with the access panel open. See section 3.5 for tape installation.
Figure 2.2
IMPORTANT : End-of-the-Line filters or In-Line filters are required at all times on each channel.
See section 6.2

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2.3 Internal Layout – Service Area
Internal access to the CL96 for installation and service uses the keyed handle located on the right side of the
front panel. Figure 2.3 shows the internal layout of the CL96 with the service door open. The door should be
opened by trained service personnel (See section 6.2 )
Figure 2.3
WARNING: Electric shock possible. Turn off the unit and disconnect A/C power to the unit
before opening the service door
2.4 Password Security
Access to many of the features is controlled through password protection which is entered through the screen
displayed in figure 2.4.
Figure 2.4

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When someone attempts to access a screen that is password protected, the screen shown in figure 2.4 will
appear (see important note below). Several of the setup & configuration screens of the CL96 require entry of
an administrative password. Factory service screens require entry of a service password - see section 7.
2.5 USB Storage
The CL96 uses a removable USB drive to store historical information including concentration logging, event
history, configuration information, and TWA data. USB storage drives may be purchased through DOD
Technologies – see Appendix A.
IMPORTANT : Once a password is entered it remains active for up to 1 minute from entry so that
it does not need to be repeatedly entered when switching between screens. Please remember
that anyone using the touch screen may access restricted screen locations during this time if the
machine is left unattended.
NOTE : The administrative password is included on a separate page shipped with your unit. It is
suggested that you remove the page and keep it in a safe and secure place. If you forget or lose
your password, please contact DOD Technologies, Inc. You can change the passwords on the
menu in the “Setup” area – see chapter 6. See Chapter 8 for contact information.

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ChemLogic® CL96 Operating Manual
Chapter 3 – Installation
WARNING: Electric shock possible. Turn off the unit and disconnect A/C power to the unit
before servicing.
WARNING: If the CL96 is used in a manner not specified by the manufacturer, the
protection provided by the equipment may become impaired.
3.1 Selecting a Location
The CL96 is designed for safe use under the following conditions:
•Indoor use only
•Altitude up to 2,000 m
•Temperatures 5°C - 40°C
•Maximum relative humidity 80% for temperatures up to 31°C decreasing linearly to 50% relative
humidity at 40 °C
•110 VAC supply voltage fluctuations up to +/- 10% of the nominal voltage
•Transient Levels : Impulse withstand (overvoltage) category II of IEC 60364-4-443
•IP Rating IP2x
The CL96 should be placed in a location as central as possible to the locations being monitored while
considering the following restrictions:
•The maximum sample line length is 400 ft (121 m). Using the shortest possible sample line length will
reduce transport times and increase the response time of the CL96. (see Appendix C)
•A/C power is required to the unit.
•Locate near proper ventilation keeping in mind the maximum length of the exhaust tubing is 25ft.
•The CL96 requires stable temperature and humidity levels within range to operate properly.
Do not place in a location which will expose the CL96 to moisture, dust, corrosive gas, or any unusual
environmental conditions which could damage the unit and/or cause it to operate inaccurately.
3.2 Unloading / Loading & Installation
The Cl96 rests on four rollers which can be locked in place and bolted to the floor if necessary.
CAUTION: Care must be taken when loading, unloading, and moving the CL96. The CL96 is
a heavy piece of equipment which could cause injury or death if not handled properly. Make
sure the rollers are operating properly and only move the CL96 on a level surface.

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3.3 Sample Tubing
Sample tubing is connected to the CL96 on the top the unit. All sample tubes are 1/4” OD x 3/16” ID Teflon
FEP (400 ft max length) which may be purchased from DOD Technologies, INC (See Appendix A). Fully
depress each sample tube into the proper hole when attaching. To detach the tube, push on the collet and pull
the tubing out.
3.3.1 End-of-Line Particulate Filters
End of line particulate filters must be installed on all sample lines at all times to prevent damage to the
unit. Unused lines must either be plugged or have a filter installed. Filters require regular maintenance – see
chapter 6.
End of line particulate filters may be purchased from DOD technologies (see appendix A).
3.4 Exhaust Tubing
The exhaust line must be 3/8” OD x 1/4” ID tubing with a maximum length of 25ft. Polyethylene is
recommended although polypropylene or Teflon may also be used. Exhaust tubing may be purchased from
DOD technologies (see appendix A)
3.5 A/C Power
When connecting the A/C power to the CL96 assure that all of the following requirements are met:
•A building circuit breaker is required.
•The circuit breaker must be installed in a suitable location that is easily reached.
•The circuit breaker must be labeled as the disconnect device for the CL96.
•The circuit break must break both poles.
See system specifications in Appendix C for power requirements.
WARNING: The detachable power cord or the supply line wiring must meet the ratings
specified in Appendix C under system specifications.
IMPORTANT : All sample tubing used with the CL96 must be ¼” OD x 3/16” ID FEP Teflon. Use
of any other tubing may damage the CL96 and/or cause inaccurate gas concentration readings.
IMPORTANT : All points require filtration to prevent dust accumulation in tubing and internal
damage to the CL96. Dust that collects in the tubing or the internal system may cause sample
loss and inaccurate concentration readings.

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3.6 Output Wiring
See Appendix B for a listing of various output module connections available on the CL96.
3.6.1 Standard Output Wiring
The standard output modules included with the system require an external 24V supply connected to the CL96
to supply power for the outputs.
Use only AWG22 to AWG18 twisted wire (wire sizes UL1015 and UL1007)
Strip from .26” to .31”(6.5mm to 8.0mm) from each wire to insert into the connector.
To connect the wires to the spring-loaded output connector:
•Insert the screwdriver into the square shaped hole which will open the round hole for the wire.
•Continue to hold the screwdriver while inserting the wire into the round shaped hole.
•While holding the wire in place remove the screwdriver which closes the clamp onto the wire.
•IMPORTANT : Be sure the wire is inserted completely into the hole. Failure to do so could result in
system failure, electrical shock.
•To remove a wire, re-insert the screwdriver in the hole as described in step 1 and gently pull the wire out
while the spring is compressed.

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Chapter 4 – Setup & Configuration
4.1 Set System Date and Time
See section 6.2.e
4.2 Gas Selection
Each point on the CL96 must be setup for the appropriate gas and configured accordingly. See section 6.2.a
for information on selecting the gas for each point.
4.3 Alarm Settings
See section 6.2.a for information on how to adjust the alarm settings after the gas has been selected for each
point.
4.4 Output Contacts
The CL96 supports both energized and de-energized outputs and may be configured for either latching or non-
latching faults/events.
When configured for energized relays, the outputs are normally in a high state and change to a low state when
the corresponding fault/alarm occurs. De-energized relays work in the opposite manner. When the power is
ON, the Power Loss relay is always in the normally high state.
When latched outputs are selected any fault or alarm that occurs will remain until the ‘fault reset’ button is
touched. If non-latching outputs are selected the output will reset automatically if and when the condition that
caused the fault/alarm goes away.
4.5 Concentration Logging
Three levels of concentration logging can be configured in the CL96
•>0 – All concentration detected > = LDL are added to the concentration log.
•AP1 – Anytime alarm level 1 is reached, the concentration is added to the log.
•AP2 – Anytime alarm level 1 is reached, the concentration is added to the log.
For AP1 or AP2 logging the system will continue to log concentrations as long as the alarm level is active. If
latching faults are enabled the system will continue to log until the ‘fault reset’ button is touched.
NOTE : A message is added to the event log each time the ‘fault reset’ button is touched.

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4.6 Install New Tape
See section 7.3 for installation instructions.
4.7 USB Storage
The use of USB Storage drive is required to retain historical and performance of information including events,
alarms, and gas concentrations. High reliability USB Storage drives are available from DOD technologies (see
Appendix A) and at most retail electronic stores. See section 7.5 for information on inserting and replacing a
USB drive. See also appendix F for information on the data set stored.
4.8 Setup Complete
The CL96 is ready for gas detection and analysis.

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Chapter 5 General Machine Operation
5.1 Introduction
The touch screen on the CL96 is used for all configuration and control of the unit. Analysis mode is active by
default approximately 2 minutes after power on unless an operator intervenes. The machine is designed to
continually monitor for gas 24/7. Various tasks can be completed while remaining in analysis including
viewing faults and events, viewing Concentration history & TWA logs, checking point configuration and flow
limits. Access to the help menu is also available while remaining in analysis.
Analysis is started either by:
1. Power on timeout without user intervention, approx. 2 minutes)
2. Touching the Start Analysis button for a specific analyzer on the Load Tape screen.
3. Touching the ‘Analysis’ button on the Main Menu which will start analysis for all installed analyzers at
the same time.
Analysis will continue until one of the following occur:
1. Power loss.
2. Touching the ‘Stop Analysis’ button for a specific analyzer on the Load Tape screen. (password may be
required)
3. Entering Setup by touching the Setup button on the main menu and entering an appropriate password
which will halt analysis on all analyzers.
4. A critical machine fault which may stop an individual analyzer or the entire CL96.
5.2 General Screen Navigation
Figure 5.2.1
Figure 5.2.1 shows a portion of the main menu that appears at the top when the machine is powered on. The
menu system on the CL96 allows simple access to all the functionality of the system with a simple
touchscreen interface. The selected item on the menu (“Analysis” on the figure 5.2.1) will appear in slightly
larger BOLD text with a lighter shade of gray as the background.
A few things to know about all the menus on the CL96:
•The background color of the top menu area always indicates the status of the machine and will match
the color of the optional light attachment. Table 5.2 explains the colors:

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Not installed
Idle (Not analyzing)
Analysis Active
Maintenance Fault
Critical fault
Gas Alarm
Table 5.2
•Table 5.2 lists the colors in priority from lowest to highest since only 1 color will be displayed at a time.
For example, if any channel indicates a Gas Alarm the menu will appear red until the gas is no longer
detected or the alarm is cleared. If any point has a low flow the menu will appear yellow, etc.
•On the main menu you can access any of the screens on the menu without exiting analysis except the
‘Setup’ button which will exit analysis and bring up the Setup sub-menu. Note that the ‘Setup’ button
may require a password depending on the configuration of the CL96.
•Items with a down arrow next to them (such as ‘History’ in figure 5.2.1) indicates that the button will
bring up a sub-menu of screen selections.
•When a sub-menu is selected the new menu will replace the previous menu and will always include the
‘BACK’ button at the start which will return to the previous menu (see figure 5.2.2).
•Note in figure 5.2.2 the background color is yellow indicating a Maintenance fault (see section xx).
Figure 5.2.2