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

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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.

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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.

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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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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.

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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

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Chapter3-Installation
3.1 Selecting a location
The CL1 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 150 ft. for all gases other than Diisocyanates.
♦Diisocyanates have a 6” maximum sample line
♦Using the shortest possible sample line length will reduce transport times and increase
the response time of the CL1.
♦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 CL1 requires stable temperature and humidity levels within range to operate
properly.
3.2 Mounting
Refer to figure 3.1 for dimensional requirements for wall mount. Be sure the CL1 is properly
secured to the wall.

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Figure 3.1

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3.3 Sample Tubing
Sample tubing connects to the CL1 through the inlet on the bottom of the unit. (see Figure
3.2). Sample tubing must be FEP 1/4 OD x 1/8 ID (150 ft max length – 6” for diisocyanates)
which may be purchased from DOD Technologies, INC (See Appendix A).
Figure 3.2
Fully depress the sample tube into fitting past the O-Ring when attaching. To detach the tube,
push on the collet and pull the tubing out.
3.3.2 End of line particulate filters
An end of line particulate filter must be used on all gasses except Diisocyanates to prevent loss
of concentration. 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 ¼”OD x 3/16” 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
A 6ft power cord is included – DO NOT use extension cords with the CL1. Longer cords are
available from most electrical supply stores.
3.6 Output Wiring
The output relays for Alarm Level 1 and System Fault are rated at 6 amp maximum.
The 4-20ma output is adjustable within the CL1 to increase precision. When not in analysis
the CL1 will output the 2ma calibrated value. There is a maximum of 500 ohm load
impedance on the 4-20ma circuit.
IMPORTANT:
The CL1 requires filtration to prevent dust accumulation in tubing
and internal damage to the unit. Dust that collects in the tubing or the internal system
may cause sample loss and inaccurate gas concentration readings.
IMPORTANT:
Sample tubing used with the CL1 must be 1/4”OD x 1/8” ID FEP.
Use of any other tubing may damage the CL1 and/or cause inaccurate gas
concentration readings.
Gas inlet
on bottom
of CL1

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See Appendix B for a listing of output module connections.
DANGER:
Before doing any wiring modifications be sure that power to
the CL18 is disconnected.

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Chapter4–Setup&Configuration
Follow t is c ecklist to configure t e CL1 for first time operation.
1. ___ Set passwords (section 5.6.c)
2. ___ Set system date and time (section 5.5.g)
3. ___ Gas selection (section 5.5.i)
Appendix E contains the specifications for each gas.
4. ___ Alarm level settings (section 5.4.e)
5. ___ Latching relays (section 5.5.c)
6. ___ Energized Relays (section 5.5.e)
7. ___ Idle Timeout (section 5.5.f)
8. ___ Testing Contacts (section 5.4.g)
9. ___ Adjustment of 4-20 ma (section 5.5.h)
10. ___ Install new ChemLogic tape (section 6.3)
11. ___ Install removable media (section 6.6)
12. ___ Format removable media (Appendix F.3)
13. ___ Tape Saver Mode (TSM section 5.5.b)
14. ___ Grease the Gate Cam (section 6.7)
Setup complete - Ready for monitoring.

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Chapter5–BasicOperation
5.1 Using the keypad
The CL1 is controlled using the keypad located around the display. All of the display screens
are accessed through a simple menu system.
Figure 5.1
1) The arrow keys located under the screen are used for two purposes.
a. To navigate through the menus using the <ENTER> key to select the highlighted
item on the menu. In most cases the <ESC> key will exit the current screen and
return to the top of the previous menu.
b. To select among multiple data fields on some of the screens for editing.
2) The arrow keys on the sides of the display referred to as “soft keys” are used only when
associated with a button on a screen. The use of these keys varies from screen to screen – see
the detailed descriptions later in this chapter.
3) When numeric entry is required on any screen the following procedure is used.
1. Use the arrow keys below the screen to select which field to edit. The currently
selected box will have a dashed line around it.
2. Press the <ENTER> key first
3. Use the numeric/function keys to enter the value
4. Also note the up arrow may be used for +/- and the down arrow may be used for the
decimal point when necessary.
5. Press the <ENTER> key again to complete the entry
NOTE: The <F1> key is used to exit analysis and return to the main menu.
Note 2
Note
1
Note
3

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5.2 Alarm & Fault screens
Three types of messages used in the CL1:
1. Alarm messages (level 1 and level 2)
2. System faults (critical faults that terminate and/or prevent analysis)
3. Event messages (warnings, non-critical faults, and various events)
See Appendix D for a description of each message. The history log keeps the most recent 128
messages of any type in memory at all times. All three types of messages are also logged to
the Micro SD card if present.
Various screens are used in the CL1 to show some or all of the messages (figure 5.2). Each
of these screens work in a similar manner.
Figure 5.2
The arrow next to the upper left soft key indicates to press that key to view the full log. When
the soft key is pressed a screen similar to figure 5.3 will be displayed. Pressing the <ESC>
key will return to the previous menu or screen.
Figure 5.3
From the screen shown in figure 5.3 the arrow keys below the screen allow scrolling of the
messages in the log. On some of the fault/event screens the <F4> key will acknowledge all
the current fault/events. NOTE: The history log does not allow messages to be cleared. The
details for each screen in section 5.4 – 5.6 will describe which keys may be used.
Pressing the <ESC> key once will return to the screen in figure 5.2. Pressing the <ESC> key
again from that screen will return to the previous menu or screen.

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CL1 Menu Overview
Note 1: T e setup menu is not password protected by default.
Note 2: T e service menu is password protected by default.
Passwords can be changed/cleared in the Password screen on the Service Menu (5.6.c)
5.3 Power on Initialization
When the CL1 is powered on it will begin with an initialization screen (figure 5.4) which is
followed by the restart screen (figure 5.5).
Figure 5.4 Figure 5.5
If the operator touches the <MENU> soft key before the timer reaches 0 the Main
Menu(section 5.4.) appears otherwise after a timeout the system will automatically start
analysis (section 5.4.a)
5.4 Main Menu
Once the CL1 is configured the main menu contains all the screens necessary for normal
operation. The main menu is not password protected.
Start Analysis
System Faults
Gas Alarms
Gate & Tape
Alarm Levels
Event/Alarm History
Test Alarms
Setup Menu
Service Menu
Main Menu
Optic Calib.
Passwords
Status
Optic Config
Clear History
Service Menu (5.6)
See Note 2
Main Me
nu (5.4)
Setup Mode
Auto Analysis Timer
Main Menu (return to)
Tape Saver
Latching Relays
Enable Pumps
Enable Points
Alarm Relays
Idle Timeout
Date/Time
Test 4-20ma
Select Gas
Conc. Logging
Conc. Logging
Setup Menu (5.5)
See Note 1
Power Up (5.3)

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Figure 5.6
Each selection on the main menu is detailed below
5.4.a Start Analysis (Figure 5.7)
Selecting this menu item will bring up the analysis screen below and start gas analysis.
Pressing <F1> during analysis will end analysis and return to the main menu.
Figure 5.7
The screen continuously displays the current gas concentration as long as the system remains in analysis mode.
When the concentration exceeds one or both of the alarm levels the text “Alarm 1” and “Alarm 2” will blink
appropriately. Anytime Alarm 1 is active the concentration display will also blink. When the concentration
passes the alarm levels the corresponding alarm output relay is triggered. The trigger will remain set depending on
the setting of Latching Relays – see section 5.4.c .
The bar graph on the right side of the display reflects the % of full scale for the current concentration reading. At
the lower left of the screen the display will show ‘P1’ or ‘P2’ if a pump is disabled either manually or
automatically. See section 5.4.d
During analysis the two keys on the right side of the display are active. When pressed the upper right key next to
the alarm levels will display a screen showing the current alarm messages. Analysis remains active while this
screen is displayed. If alarms are active they may be cleared by pressing <F4> (see alarm screen operation in
section 5.3.f). NOTE : If an alarm is cleared but gas is still present above the present alarm level the alarm will
immediately trigger once again. Pressing <ESC> will return to the analysis screen.
An asterisk next to the lower right soft key indicates that there are new warning/fault messages. Pressing the key
on the lower right next to the asterisk will display the messages while remaining in analysis mode. Any active
warning/fault messages may be cleared by pressing <F4> (see alarm screen operation in section 5.3.f). Pressing
<ESC> will return to the analysis screen.
Current gas being monitored
and scale used
Blinking
“Full Scale” text
displayed w en
appropriate
Tape Saver Mode
indicator and timer.
See Sec 5.4.b
Press to display current
gas alarms
Current gas concentration and units
Press to display
current
warnings & events
Ga
s concentration bar
grap displays % of full
scale.
Text blinks during alarm
Current alarm levels
P1 or P2 flas ing display
w en pump disabled.
Indicates new
warning/event message(s)
W en Tape Saver Mode
is NOT active, displays
# of days remaining on
C emlogic Tape.
WARNING – Tape Saver Mode may affect the display of actual gas concentration. See
section 5.5.b for a complete explanation of Tape Saver Mode (TSM).

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5.4.b System Faults (Figure 5.8)
See section 5.2 for the use of the fault/alarm screens. The <F4> key is available to clear
messages from the detail screen. The <ESC> key will return to the main menu.
Figure 5.8
5.4.c Gas Alarms (Figure 5.9)
See section 5.2 for the use of the fault/alarm screens. The <F4> key is available to clear
messages from the detail screen. The <ESC> key will return to the main menu.
Figure 5.9
5.4.d Gate & Tape (Figure 5.10)
Touch the lower left <GATE> soft key to open or close the gate. When a new Chemlogic
tape is loaded press the <RESET> soft key to reset the counter for a new tape. The tape
windows remaining displays the number of tape advances expected before the tape is empty.
This number is used in the calculation of the warning message “Chemlogic Tape Low”.
Press the <DONE> soft key to return to the main menu.
Figure 5.10
5.4.e Alarm Levels (Figure 5.11)
Use the arrow keys below the screen to select between Alarm 1 and Alarm 2. Notice the
dotted line around the currently selected field. To enter a new alarm level follow the
procedure outlined in section 5.1There are several errors that can occur and will be displayed
in the “Status Area” of the screen. . Press the <DONE> soft key to return to the main menu.
Figure 5.11
Status Area