DOD Technologies ChemLogic 1 User manual

ChemLogic 1
Single Point Continuous Gas Monitor
User’s Manual

DECLARATION OF CONFORMITY
DOD TECHNOLOGIES INC.
740 McArdle DR. Unit C
Crystal Lake, Illinois 60014
We declare under our sole responsibility that the product described as:
ChemLogic 1 (CL1)
Complies with the requirements of the Directives:
- Machinery Directive 98/37/EC (amended);
- Low Voltage Directive 2006/95/EC
- Electromagnetic Compatibility Directive 2004/108/EC
Standards considered:
EN 12100-1, EN 12100-2, EN 60204-1, EN 61000-6-2, EN 61000-6-4
Date: 12 / 3 / 2007 At: 10:00 am
Daniel ODonnell
Daniel ODonnellDaniel ODonnell
Daniel ODonnell
Daniel O'Donnell

ChemLogic1User’sManual
Default Passwords
Setup Menu 0
Service Menu 1234
DOD Technologies, INC
www.dodtec.com
740 McArdle Dr. • Unit C
Crystal Lake, IL 60014
Phone [phone] • Fax [phone]

TABLE OF CONTENTS
IMPORTANT ............................................................................................................................................... 1
CHAPTER 1 - OVERVIEW........................................................................................................................ 2
1.1 Introduction....................................................................................................................................... 2
1.2 Sampling and Monitoring ................................................................................................................. 2
1.3 Flow Connections.............................................................................................................................. 2
1.4 Electrical Connections ...................................................................................................................... 2
1.5 Theory of operation........................................................................................................................... 2
CHAPTER 2 - FEATURES ......................................................................................................................... 3
2.1 External Layout................................................................................................................................. 3
2.1.1 Maintenance door .......................................................................................................................... 3
2.1.2 Keypad & Display ........................................................................................................................... 3
2.1.3 ChemLogic tape and Take-up Reel................................................................................................ 3
2.1.4 Gas Inlet/Exhaust........................................................................................................................... 3
2.1.5 A/C Power & Switch....................................................................................................................... 4
2.1.6 14 Pin I/O Connector ..................................................................................................................... 4
2.2 Maintenance area.............................................................................................................................. 4
2.3 Internal Layout – Service area ......................................................................................................... 4
2.5 Micro Secure Digital (SD) card ........................................................................................................ 5
CHAPTER 3 - INSTALLATION................................................................................................................ 6
3.1 Selecting a location ........................................................................................................................... 6
3.2 Mounting ........................................................................................................................................... 6
3.3 Sample Tubing .................................................................................................................................. 8
3.3.2 End of line particulate filters ......................................................................................................... 8
3.4 Exhaust tubing .................................................................................................................................. 8
3.5 A/C Power.......................................................................................................................................... 8
3.6 Output Wiring.................................................................................................................................... 8
CHAPTER 4 – SETUP & CONFIGURATION......................................................................................... 9
CHAPTER 4 – SETUP & CONFIGURATION....................................................................................... 10
CHAPTER 5 – BASIC OPERATION ...................................................................................................... 11
5.1 Using the keypad ............................................................................................................................. 11
5.2 Alarm & Fault screens .................................................................................................................... 12
CL1 Menu Overview.............................................................................................................................. 13
5.3 Power on Initialization.................................................................................................................... 13
5.4 Main Menu ...................................................................................................................................... 13
5.4.a Start Analysis (Figure 5.7)........................................................................................................... 14
5.4.b System Faults (Figure 5.8)........................................................................................................... 15
5.4.c Gas Alarms (Figure 5.9)............................................................................................................... 15
5.4.d Gate & Tape (Figure 5.10)........................................................................................................... 15
5.4.e Alarm Levels (Figure 5.11) .......................................................................................................... 15
5.4.f Event/Alarm History (Figure 5.12) ............................................................................................. 16
5.4.g Test Alarms (Figure 5.13) ............................................................................................................ 16
5.5 Setup Menu (Figure 5.14)............................................................................................................... 17
5.5.a Main Menu ................................................................................................................................... 17
5.5.b Tape Saver (Figure 5.15) (Default configuration : Disabled) .................................................... 17
5.5.c Latching Relays (Figure 5.17) (Default configuration : ON)................................................... 18
5.5.d Enable Pumps (Figure 5.18) (Default configuration : Enabled) ............................................... 19
5.5.e Enable Points (Default configuration : Only available on CL2) ................................................ 19

5.5.f Energized Alarm Relays (Figure 5.19) (Default configuration : Off) ....................................... 19
5.5.g Idle Timeout (Figure 5.20) (Default configuration : 45 Minutes)........................................... 19
5.5.h Date/Time (Figure 5.21) .............................................................................................................. 20
5.5.i Test 4-20ma (Figure 5.22) ............................................................................................................ 20
5.5.i Select Gas (Figure 5.24)............................................................................................................... 20
5.5.j Conc. Logging (Figure 5.25) ........................................................................................................ 20
5.6.a Main Menu ................................................................................................................................... 22
5.6.b Optic Calib (Figure 5.26) ............................................................................................................. 22
5.6.c Passwords(Figure 5.27)................................................................................................................ 22
5.6.d Optic Config ................................................................................................................................. 22
5.6.e Status............................................................................................................................................. 23
5.6.f Clear History (Figure 5.28) .......................................................................................................... 23
5.6.g Configuration ............................................................................................................................... 23
CHAPTER 6 - MAINTENANCE.............................................................................................................. 24
6.1 Maintenance Door Access............................................................................................................... 24
6.2 Service Door Access ........................................................................................................................ 24
6.3 ChemLogic Paper tape .................................................................................................................... 25
ChemLogic Paper Tape Path ................................................................................................................ 25
6.4 End of line particulate filters .......................................................................................................... 26
6.4 End of line particulate filters .......................................................................................................... 27
6.5 Flow adjustment .............................................................................................................................. 27
6.6 Micro Secure Digital (SD) Card replacement ................................................................................ 27
6.4 End of line particulate filters .......................................................................................................... 28
6.7 Fuse Replacement ........................................................................................................................... 28
6.8 Apply grease periodically ................................................................................................................ 28
APPENDIX A – ACCESSORIES ............................................................................................................. 30
APPENDIX B – I/O CONNECTION DETAIL ....................................................................................... 31
APPENDIX C – TECHNICAL SPECIFICATIONS............................................................................... 32
APPENDIX D - SYSTEM EVENT MESSAGES..................................................................................... 33
APPENDIX E - GAS SPECIFICATIONS ............................................................................................... 36
APPENDIX F – REMOVABLE MEDIA ................................................................................................. 37
F.1 Concentration Log Files (YYMMDD*.CSV) ................................................................................. 37
F.2 Event Log Files (YYMMDD*.CSV) ............................................................................................... 37
F.3 Formatting Micro SD Disks ........................................................................................................... 38
APPENDIX G – CHEMLOGIC CASSETTES........................................................................................ 40
APPENDIX H – OPTIC BLOCK CLEANING PROCEDURE............................................................ 41

C L 1 U S E R S G U I D E D O D T E C H N O L O G I E S , I N C
Rev 10.07 Page 1
IMPORTANT
Only trained operators must be allowed to work on the Cl1.
ELECTRICAL HAZARD
The CL1 may only be serviced by trained service personnel.
Contact the manufacturer for more information
.
Be sure to read t is manual in its entirety before installing and operating t e CL1. Contact t e
manufacturer wit any questions regarding t e installation or use of t e CL1.
IMPORTANT
: Read Appendix G before handling Che Logic Cassett
es.

C L 1 U S E R S G U I D E D O D T E C H N O L O G I E S , I N C
Rev 10.07 Page 2
Chapter1-Overview
1.1 Introduction
The DOD Technologies ChemLogic 1 (CL1) continuously monitors a single location
(called a point) for toxic and corrosive gas. It responds to gas that exceed a programmed
alarm level by:
• Triggering visual alarms on the display that warn of high or low concentrations
• Triggering relays or activating analog outputs to external devices
• Displaying the gas type and gas concentration
• Recording the alarm information and storing it to removable storage.
The CL1 triggers relays for two levels of gas concentrations. These programmable limits
are factory-set at 1 TLV and 2 TLV for their respective gases.
The point may be up to 150feet (45 m) from the CL1 location depending on the type of
gas being monitored. This allows operators to monitor the gas concentration in an area
removed from the location where gas may actually be leaking.
The CL1 provides a fast response to a wide range of gases. It was designed for maximum
uptime, so routine maintenance and service can be performed quickly and easily.
The CL1 uses DOD Technologies ChemLogic paper tape technology for fast and
accurate gas detection.
1.2 Sampling and Monitoring
The system draws sample flow through the inlet on the bottom of the unit and across the
ChemLogic tape. The gas is then exhausted through a port on the side of the CL1.
1.3 Flow Connections
Flow connections consist of “quick-connect” ports on the bottom and side of the CL1.
There is one inlet and one exhaust outlet.
1.4 Electrical Connections
The unit is powered with a standard AC Power plug. A single 14 pin connector on the side of
the CL1 provides all electrical connections for the outputs and remote reset.
1.5 Theory of operation
The sample flow is diverted across the ChemLogic Tape. The CHEMLOGIC 1 uses an
advanced optical detection system to measure the light level reflected from the ChemLogic
tape. As the target gas is detected, the color of the of the ChemLogic tape changes. This
color change results in a loss of reflected light across the ChemLogic tape. This loss of
reflected light is detected by the advanced optics system in the CHEMLOGIC 1. The
CHEMLOGIC 1 will then report an appropriate gas concentration reading and/or a gas alarm.

C L 1 U S E R S G U I D E D O D T E C H N O L O G I E S , I N C
Rev 10.07 Page 3
Chapter2-Features
2.1 External Layout
Figure 2.1
2.1.1 Maintenance door
The maintenance door allows easy access to the ChemLogic tape and the display/keypad. The
latches on the side of the unit are used to open & close/secure the door.
2.1.2 Keypad & Display
The CL1 uses a two color LCD display with a 20 button keypad including 4 programmable
“soft keys”. See chapter 5 for a complete description on the use of the keypad and display.
2.1.3 ChemLogic tape and Take-up Reel
ChemLogic paper tapes are accessed by opening the maintenance door. Refer to chapter 6
regarding tape installation/replacement.
2.1.4 Gas Inlet/Exhaust
The gas being monitored flows through the inlet on the bottom of the unit, across the paper
tape and out the exhaust port on the side of the CL1. Sample tubing and exhaust use a quick
connection system for simple installation. See section 3.3 for information on connecting the
sample and exhaust tubing.
IMPORTANT: T e maintenance door s ould remain closed and latc ed except w en
c anging t e C emLogic tape.
14 pin
I/O Connector
A/C Power & Switch
ChemLogic Tape
Maintenance Door
Take-up reel
Exhaust Outlet
Keypad & Display
Gas tubing inlet
(underside)
Door latches
(side of unit)

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Rev 10.07 Page 4
2.1.5 A/C Power & Switch
A/C power is connected on the left side panel with a standard power cord. The on/off power
switch is located adjacent to the power cord connection.
2.1.6 14 Pin I/O Connector
The connector on the side of the unit connects to alarm relays, fault relays, 4-20ma output, and
the remote reset input.
2.2 Maintenance area
The maintenance area allows easy access for changing ChemLogic tape in the CL1. Figure
2.2 shows the internal layout with the access panel open. See section 6.3 for tape installation.
Figure 2.2
2.3 Internal Layout – Service area
Internal access to the CL1 for service uses the latches located on the right side of the front
panel. Figure 2.3 shows the internal layout of the CL1 with the service door open.
The door should be opened by trained service personnel (See section 6.2)
. IMPORTANT:
End of line filters are required. See section 6.4
DANGER:
Turn off the unit and disconnect A/C power to the unit before
opening the Service Door.

C L 1 U S E R S G U I D E D O D T E C H N O L O G I E S , I N C
Rev 10.07 Page 5
Figure 2.3
2.5 Micro Secure Digital (SD) card
The CL1 uses a SD card to store historical information including concentration logging, event
history, configuration information, and TWA data. SD cards may be purchased through DOD
Technologies – see Appendix A.
Inside w/Serv
ice Door
open
Back of Service Door
Output Connection Block
SD Card access door
Easy access
long life pumps
Power Supply