DOD Technologies ChemLogic Revive CL4R User manual

ChemLogic®Revive™ CL4R
4-Point Continuous Gas Detector
Operating Manual

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ChemLogic® Revive™ CL4R 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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Table of Contents
Chapter 1 – Overview..................................................................................................................................................................... 6
1.1 Introduction ........................................................................................................................................................................... 6
1.2 Sampling and Monitoring ..................................................................................................................................................... 6
1.3 Theory of Operation .............................................................................................................................................................. 6
Chapter 2 – Features & Layout...................................................................................................................................................... 7
2.1 Features ................................................................................................................................................................................. 7
2.1.1 Warning Labels, Descriptions, & Danger Zones..................................................................................................... 7
2.1.2 Touch Screen Display ............................................................................................................................................. 8
2.1.3 A/C Power & Switch ............................................................................................................................................... 8
2.1.4 Flow Connections & Adjustments.......................................................................................................................... 8
2.1.5 ChemLogic Cassette ............................................................................................................................................... 9
2.1.6 Cassette Take-Up Reel ........................................................................................................................................... 9
2.1.7 Tubing Connections................................................................................................................................................ 9
2.1.8 Alarm Outputs........................................................................................................................................................ 9
2.2 External Layout.................................................................................................................................................................... 10
2.2.1 Maintenance Area................................................................................................................................................ 10
2.3 Internal Layout..................................................................................................................................................................... 11
2.3.1 Service Area ......................................................................................................................................................... 11
2.4 Password Security .............................................................................................................................................................. 12
2.5 Data History Storage........................................................................................................................................................... 12
Chapter 3 – Installation ............................................................................................................................................................... 13
3.1 Selecting a Location ........................................................................................................................................................... 13
3.1.1 Mounting Options ................................................................................................................................................ 13
3.1.2 Product Dimensions ............................................................................................................................................. 13
3.2 Sample Tubing .................................................................................................................................................................... 15
3.2.1 Tubing Connections.............................................................................................................................................. 15
3.3 Sampling Environment........................................................................................................................................................ 16
3.3.1 End-Of-Line Particulate Filters ............................................................................................................................. 16
3.4 Exhaust tubing..................................................................................................................................................................... 16
3.5 Output Wiring....................................................................................................................................................................... 16
3.6 Sample Line Particulate Filter Installation......................................................................................................................... 17
3.7 Pump Installation ................................................................................................................................................................ 17
3.8 Pump Exhaust Line Installation.......................................................................................................................................... 17
3.8.1 Exhaust Line Installation Guide............................................................................................................................ 17
3.8.2 Exhaust Tubing Specifications.............................................................................................................................. 17

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3.9 Loading the ChemLogic®Cassette .................................................................................................................................... 18
3.10 Powering ON/OFF ............................................................................................................................................................. 18
Chapter 4 - Setup & Configuration............................................................................................................................................... 19
4.1 Set System Date and Time ................................................................................................................................................. 19
4.2 Gas Selection....................................................................................................................................................................... 19
4.3 Alarm Settings..................................................................................................................................................................... 19
4.4 Output Relays ...................................................................................................................................................................... 19
4.5 Concentration Logging ....................................................................................................................................................... 19
4.6 Install New ChemLogic Cassette ....................................................................................................................................... 20
4.7 Setup Complete................................................................................................................................................................... 20
Chapter 5 – Basic Operation ....................................................................................................................................................... 21
5.1 CL4R Menu Overview .......................................................................................................................................................... 21
5.2 Initialization ......................................................................................................................................................................... 22
5.2.1 Keyboard Function ............................................................................................................................................... 22
5.3 Setup / Main Menu.............................................................................................................................................................. 23
5.3.1 Gas & Alarm Settings Menu ................................................................................................................................. 24
5.3.2 Set Date/Time ...................................................................................................................................................... 25
5.3.3 Load Tape ............................................................................................................................................................. 26
5.3.4 Flow Adjustment .................................................................................................................................................. 27
5.3.5 Calibration Factors ............................................................................................................................................... 28
5.3.6 Set & Test Outputs ............................................................................................................................................... 28
5.3.7 Factory Settings.................................................................................................................................................... 30
5.3.8 Event History........................................................................................................................................................ 30
5.4 Concentration Log............................................................................................................................................................... 31
5.4.1 Concentration Configuration ............................................................................................................................... 32
5.5 Analysis Mode..................................................................................................................................................................... 32
5.5.1 Point Detail Screen............................................................................................................................................... 34
5.6 Time Weighted Average (TWA).......................................................................................................................................... 35
Chapter 6 – Maintenance ............................................................................................................................................................ 36
6.1 ChemLogic Cassettes......................................................................................................................................................... 36
6.1.1 Installing/Replacing ChemLogic Cassettes........................................................................................................... 36
6.2 End-Of-Line Particulate Filters............................................................................................................................................ 37
6.3 Flow Adjustment ................................................................................................................................................................. 39
6.4 Apply Grease ....................................................................................................................................................................... 39
6.5 Fuse Replacement .............................................................................................................................................................. 39
6.6 Optics................................................................................................................................................................................... 39

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Chapter 7 – Service & Support .................................................................................................................................................... 40
Appendix A – Parts & Accessories.............................................................................................................................................. 41
Appendix B – Communication Protocols ................................................................................................................................... 42
Appendix C – System Specifications.......................................................................................................................................... 45
Appendix D – System Event Messages ...................................................................................................................................... 46
Appendix E – Gas Specifications ................................................................................................................................................ 48
Appendix F – ChemLogic Cassettes........................................................................................................................................... 51
Appendix G – Optic Block Cleaning Procedure .......................................................................................................................... 52
G.1 Basic Optics Cleaning......................................................................................................................................................... 52
G.2 Advanced Optics Cleaning ................................................................................................................................................. 53
Appendix H – 4-20mA + Relay Option Installation ..................................................................................................................... 54
H.1 4-20mA + Relay Option Overview ...................................................................................................................................... 54
H.2 Wiring and Setup ................................................................................................................................................................ 54
H.3 4-20mA + Relay Tabletop Installation ............................................................................................................................... 57
H.4 4-20mA + Relay Rack Mount Installation .......................................................................................................................... 58
Appendix I – CL4R Pump Installation ......................................................................................................................................... 59
I.1 Pump Installation Overview................................................................................................................................................. 59
I.2 Pump Installation Procedure............................................................................................................................................... 59

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Chapter 1 – Overview
1.1 Introduction
DOD Technologies’ ChemLogic®Revive™ CL4R continuous gas detector simultaneously monitors up to four
locations (or
points ) for targeted toxic and corrosive gases. The system can serve as a direct replacement for
legacy CM4 units by seamlessly connecting into an existing CM4 rack enclosure. 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 CL4R 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 CL4R 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
CL4R employs DOD Technologies’ ChemLogic colorimetric technology, utilizing ChemLogic cassettes with
chemically infused tape for fast and accurate gas detection.
1.2 Sampling and Monitoring
The system draws sample flow simultaneously from all four sample locations to the ChemLogic CL4R. Part of
the sample flow is diverted across the ChemLogic cassette where it is analyzed. All channels exhaust through
a single port.
1.3 Theory of Operation
The system simultaneously extracts ambient samples from up to four locations (or points). The sample drawn
is diverted across the ChemLogic cassette. The CL4R uses an advanced optical detection system to analyze
the ambient samples drawn to the ChemLogic cassette. As a target gas is detected, the cassette records a
colored stain from the sample pulled. This results in a loss of reflected light which is detected by the optics
system. The CL4R will then report a gas concentration reading and/or a gas alarm.
WARNING
: If the system is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.

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Chapter 2 – Features & Layout
2.1 Features
2.1.1 Warning Labels, Descriptions, & Danger Zones
The table below references the warning labels (with descriptions) that may be encountered while operating
and servicing the ChemLogic CL4R continuous gas detection system.
WARNING:
Hot Surface. This surface will be hot to the touch and may cause injury. Please avoid or
take extra caution when working near this zone.
WARNING
:
Protective Earth Ground. Terminal intended for connection to external conductor for
protection against electric shock in case of fault.
ATTENTION
:
Please refer to the operation manual for instructions for this system. If the manual is not in
your desired language, request an updated manual before using the equipment.
WARNING:
Electric Shock is possible, please use caution when accessing this zone.
WARNING
:
Moving Parts and Hand Crushing possible. Please watch hand placement when working
near this zone.

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Please be aware of the following danger zones on the ChemLogic CL4R continuous gas detection system.
Each zone contains warning labels for operator safety.
A
This danger zone is in the service access
point of the unit. Users should be
cautious of hot surfaces and the potential
of electric shock.
B
This danger zone is located on the gate
assembly. During operation, operators
could pinch fingers if not aware of hand
placement.
C
This danger zone is referencing the top of
the pump on the inside of the unit. This
area warns of electrical shock areas
within the service door of the machine.
2.1.2 Touch Screen Display
The CL4R features a 7” LCD color touchscreen with menu-driven options for simplified operator interface.
Access to menus and data entry can be performed by touching the appropriate areas on the screen – see
Chapter 5 “Basic Operation”.
2.1.3 A/C Power & Switch
A/C power inlet and ON/OFF power switch is located on the rear panel. A standard AC power cable is included.
2.1.4 Flow Connections & Adjustments

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Flow connections consist of “quick-connect” ports in the back of the CL4R unit. There are four inlets, one for
each monitored point, and one exhaust outlet.
Flow adjustments for all points is located on the right-hand facing side of the front panel. Refer to Section
5.3.4 regarding flow adjustment.
2.1.5 ChemLogic Cassette
The ChemLogic cassette is accessible from the top of the unit. The CL4R system utilizes DOD Technologies’
exclusive ChemLogic colorimetric technology. Only use ChemLogic cassettes specifically offered for the CL4R
system. Refer to Section 6.1 for additional details regarding cassette installation and replacement.
2.1.6 Cassette Take-Up Reel
An empty take-up reel must be in place when installing a new ChemLogic Cassette (see Section 6.1). All new
CL4R systems include an empty take-up reel unit. When replacing an existing cassette, the take-up reel
(containing the used cassette) must be removed and discarded. The previous ChemLogic Cassette reel –
which is now empty – should be moved over and used as the next take-up reel.
2.1.7 Tubing Connections
Sample tubing and exhaust use a quick connection system for simple installation. The connections may be
made on the rear panel. See Sections 3.2 & 3.4 for information on connecting the sample and exhaust tubing.
See also Appendix C for essential information on transport times for gas from sampling point to the CL4R.
2.1.8 Alarm Outputs
The CL4R integrates seamlessly with an existing rack enclosure infrastructure (contact us for additional
specifications) without re-wiring of outputs. The I/O (input/output) panel contains connections to 14 form C
relays to activate external devices:
•A watch dog relay (RY12) indicates power loss or a CPU failure
•Eight gas alarm relays which indicate Level 1 and Level 2 alarms
•General Alarm 1 and Alarm 2 relays activate when any point moves above the set level
•Fault relays are activated when the CL4R requires maintenance and/or service
For complete details on alarm outputs, please see Section 4.3.
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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2.2 External Layout
Figure 2.1
2.2.1 Maintenance Area
The maintenance area provides easy access for changing ChemLogic cassettes in the CL4R. Figure 2.2.1
shows the internal layout with the access panel open. See Section 6.1 for cassette installation.
Figure 2.2.1
ChemLogic® CL4R Cassette
Touch Screen LCD Display
Flow adjustment knobs
Maintenance Cover
Rack Mounting
Bracket
A/C Power & Switch (Rear)
Flow tubing & exhaust
quick-connect system
(Rear)
Take-up reel
Rack Mounting
Bracket
USB 3.0 Drive

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2.3 Internal Layout
2.3.1 Service Area
Internal access to the CL4R for installation and service is performed by removing the top cover (rear) secured
by Phillips screws. Figure 2.3 shows the internal layout of the CL4R with the top cover open.
The cover should only be opened by trained service personnel. See Chapter 7 to contact us regarding service
and support.
Figure 2.3
Inside the CL4R with
maintenance cover open
Pump
Fan
USB Memory Stick Access
Power Supply
IMPORTANT: The top cover should remain closed and secured except when
servicing critical components. Do not open the door while in Analysis Mode.
DANGER:Turn off the unit and disconnect A/C power before
opening the top cover.

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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
When an attempt is made 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 require an administrative
access password. Factory service screens require entry of a service password - see Chapter 7.
NOTE:The Administrative Password is included on the first page of this manual. It is suggested that you
remove the page and keep in a safe and secure place. If you forget or lose your password, please contact DOD
Technologies. See Chapter 7 for contact information.
2.5 Data History Storage
The CL4R uses internal memory to store historical information including concentration logging, event history,
configuration information, and TWA data. USB storage drives may also be used to collect data at the unit.
IMPORTANT: Once a password is entered it remains active for 2 minutes after
entry so that it does not need to be repeatedly entered when switching between
screens. Please keep in mind that anyone using the touchscreen may access
restricted screen locations during this time if the machine is left unattended.

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Chapter 3 – Installation
3.1 Selecting a Location
The CL4R 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. Using the shortest possible sample line length will reduce
transport times and increase the response time (See Appendix C)
•A/C power to the unit is required.
•Locate near proper ventilation (keep in mind, the maximum length of the exhaust tubing is 50 ft.)
•The CL4R requires stable temperature and humidity levels within range to operate properly.
Dust and Humidity Exposure
Placing the CL4R in a location exposed to excessive moisture, dust, corrosive gases, or any unusual
environmental conditions which could significantly damage the unit and/or cause it to operate inaccurately.
Ensure there is room behind the CL4R to service the unit and provide proper ventilation.
3.1.1 Mounting Options
The CLR4 is designed for tabletop or retrofit configuration in a rack enclosure (MDA-supplied cabinet).
The tabletop is the basic, stand-alone configuration that is used throughout this manual to show instrument
operation. Rack configurations require a separate enclosure. Please contact DOD Technologies if assistance is
required using a wall mount or rack kit (user-supplied rack) configuration.
When selecting a site for installation of the CL4R, consider the mounting option best suited for your location.
Operators can place the CL4R up to 400 feet (122 m) from monitoring points to monitor gas concentrations in
an area removed from the location where gas may be leaking.
3.1.2 Product Dimensions
Top ¾ View

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Figure 3.1
Figure 3.2
Figure 3.3
Front
Side
Rear

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3.2 Sample Tubing
Sample tubing is connected to the CL4R from the back of the CL4R. All sample tubes are 1/4” OD x 3/16” ID
Teflon FEP (500 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. Do not crimp exhaust lines or place them in an area where weight could collapse the
tubing or bend them to less than a 5-inch (12 cm) radius. Leave as many bends as possible visually exposed
for periodic visual inspection of the line for kinked or damaged tubing.
3.2.1 Tubing Connections
To prepare for installation of sample lines, remove the FEP Teflon tubing (3/16-inch I.D. x 1/4-inch O.D.).
The back of the unit includes five connections:
1 Sample Inlet - Point 1 4 Sample Inlet - Point 4
2Sample Inlet - Point 2 5 Exhaust
3Sample Inlet - Point 3
Note:
Always perform a leak check after installing all sample lines.
LEGEND
[1] Sample Inlet - Point 1
[2] Sample Inlet - Point 2
[3] Sample Inlet - Point 3
[4] Sample Inlet - Point 4
[5] Exhaust

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3.3 Sampling Environment
Before installing the CL4R, review and determine if the sampling environment locations has excessive dust or
moisture. Use an external filter at the end of all sample lines. See Appendix A for selection of appropriate filter
type for the target gas. Dust may be present due to construction or manufacturing activities. Moisture may
occur from rain entering a line at an outdoor sampling location or from condensation caused by temperature
fluctuations. Water condensation in the sample lines could cause false alarms.
NOTE: Variables such as air flow, the molecular weight and temperature of the sample gas, and the physical
conditions of the areas being monitored influence the placement of the sampling locations. You may need to
consult your company industrial hygiene or safety officer before installing sample lines to determine your
company’s policy related to sampling locations and monitoring of the desired sample gas.
3.3.1 End-Of-Line Particulate Filters
End of line particulate filters must be installed on all 4 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
Section 6.2.
End of line particulate filters may be purchased from DOD technologies (see Appendix A)
3.4 Exhaust Tubing
The exhaust line must be 1/4” OD x 3/16” ID tubing with a maximum length of 50 ft. Polyethylene,
polypropylene or Teflon may be used.
Exhaust tubing is available from DOD Technologies (see Appendix A)
3.5 Output Wiring
To restore functionality of the existing relay outputs, simply connect the 40-pin ribbon to the rear of the unit. If
a 4-20mA output is required, ensure this is requested for factory installation when ordering your CL4R unit.
See Appendix B for a listing of output module connections.
IMPORTANT: All points require filtration to prevent dust accumulation in tubing and
internal damage to the CL4R. Dust that collects in the tubing or the internal system
may cause sample loss and inaccurate gas concentration readings.

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3.6 Sample Line Particulate Filter Installation
See Appendix A to determine if you can use sample line filters with your target gas. Attach a sample line filter
to the sampling end of the line only if you have determined that environmental dust or moisture is a concern at
the sampling location.
3.7 Pump Installation
The CL4R requires installation of the pump into the system. During the shipping process, the pump is shipped
separately from the system to prevent damage. See Appendix J for complete instructions on how to install the
pump into the system.
3.8 Pump Exhaust Line Installation
This section describes exhaust connections and installation.
3.8.1 Exhaust Line Installation Guide
Properly ventilate the exhaust line, which should not exceed 50 feet (15 m) in length. If longer distances are
required, contact DOD Technologies.
•If multiple CL4R units are installed in the same location, use a separate line for each exhaust outlet
•Do not crimp exhaust lines, or place them in an area where weight could collapse the tubing, or bend
them to less than a 5-inch (12 cm) radius
•Leave as many bends as possible visually exposed for periodic visual inspection of the line for kinked
or damaged tubing
•Varying exhaust pressure can induce pump failure
3.8.2 Exhaust Tubing Specifications
The instrument includes 50 feet (15 m) of 3/16-inch (4.7 mm) I.D. x 1/4-inch (6.35 mm) O.D. polypropylene
tubing.
CAUTION:When using a sample line particulate filter, excess dirt
in the filters can slow the sample line flow and affect the
analyzer’s concentration readings. See Appendix A to determine
the appropriate filter to use in conjunction with your target gas.

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3.9 Loading the ChemLogic®Cassette
For ChemLogic® cassette loading procedures, see Section 6.1.
3.10 Powering ON/OFF
Use the rocker switch on the right rear of the unit at the power cord, to turn on power to the Model CL4R. For
Rack Mount units, use the power panel at the top of the rack. The number of each switch correlates to the
position of the CL4R unit in the rack.
Note:
The CL4R automatically enters Analysis Mode whenever it is switched on, following a brief delay.
WARNING
:.
Be sure to install the correct ChemLogic®
cassette (See Appendix A for part number information.) Make
sure the label on the ChemLogic® cassette and the label on
the analyzer correspond. Incorrect ChemLogic® cassette
replacement defeats the CL4R’s ability to warn of dangerous
gas concentrations.

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Chapter 4 - Setup & Configuration
4.1 Set System Date and Time
See Section 5.3.2
4.2 Gas Selection
Each point on the CL4R must be setup for the appropriate gas and configured accordingly. See Section 5.3.1
for information on selecting the gas for each point.
4.3 Alarm Settings
See Section 5.3.1 for information on how to adjust the alarm settings after the gas has been selected for each
point.
4.4 Output Relays
The CL4R supports both energized and de-energized relays 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.
NOTE:A message is added to the event log each time the ‘fault reset’ button is touched.
4.5 Concentration Logging
Three levels of concentration logging can be configured in the CL4R.
1. >0 - All concentrations detected >= LDL are added to the concentration log.
2. AP1 - Anytime alarm level 1 is reached, the concentrations are added to the log.
3. AP2 - Anytime alarm level 2 is reached, the concentrations are added to the log.
Regardless of which point the gas is detected on, all CL4R points are logged as long as the trigger is active. 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.

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4.6 Install New ChemLogic Cassette
See Section 6.1 for installation instructions.
4.7 Setup Complete
Enter analysis.