DOD Technologies ChemLogic 1 User manual

ChemLogic®1 & 2
Continuous Gas Monitor User Manual

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CL1 & CL2 Manual
©DOD Technologies, INC
675 Industrial Drive Bldg. A.
Cary, IL 60013
Phone [phone] • Fax [phone]

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CL1 & CL2 Manual
EC DECLARATION OF CONFORMITY
EU DECLARATION OF CONFORMITY
DOD TECHNOLOGIES INC.
675 Industrial Drive –Bldg. A
Cary, IL 60013
USA
Name and address of the company established in European Community and authorized to compile
the Technical File :
ACC - Services Contact
105 route des pommiers
Centre Ubidoca
74370 St Martin Bellevue
France
DOD TECHNOLOGIES INC. declares under our sole responsibility that the product described as:
Equipment Name: Continuous Gas Monitor
Equipment Description: Detection and measurement of toxic gases
Model: CL1/CL2
Serial number(s): _______________
Complies with the requirements of the following European Directives:
Machinery Directive 2006/42/EC;
Electromagnetic Compatibility Directive 2014/30/EU.
RoHS Directive 2011/65/EU.
Main standards considered :
EN ISO 12100 :2010.
EN 50271: 2010.
EN 60204-1:2006 +A1:2009.
EN 50270:2006.
EN 50581: 2012
Name of authorized company representative: Mr. Daniel O’Donnell
President
DOD Technologies, INC
Daniel O’Donnell
Daniel O'Donnell
Date: 05/25/18
At: Cary, Illinois USA

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CL1 & CL2 Manual
Table of Contents
Chapter 1 –Overview .................................................................................................................................................................... 7
1.1 Introduction........................................................................................................................................................................... 7
1.2 Sampling and Monitoring..................................................................................................................................................... 7
1.3 Flow Connections ................................................................................................................................................................. 7
1.4 Electrical Connections.......................................................................................................................................................... 8
1.5 Theory of Operation.............................................................................................................................................................. 8
Chapter 2 –Features ..................................................................................................................................................................... 9
2.1 External Layout ..................................................................................................................................................................... 9
2.1.1 Warning Labels, Descriptions, & Danger Zones .............................................................................................................. 9
2.1.2 ChemLogic®1 & 2 Danger Zones ................................................................................................................................... 10
2.1.3 Maintenance Door ........................................................................................................................................................... 10
2.1.4 Keypad & Display ............................................................................................................................................................. 11
2.1.5 ChemLogic®Tape and Take-up Reel ............................................................................................................................. 11
2.1.6 Gas Inlet & Exhaust.......................................................................................................................................................... 11
2.1.7 A/C Power & Switch......................................................................................................................................................... 11
2.1.8 14-Pin I/O Connector ...................................................................................................................................................... 11
2.2 Maintenance Area............................................................................................................................................................... 11
2.3 Internal Layout –Service Area .......................................................................................................................................... 12
2.4 Micro Secure Digital Card (SD Card) ................................................................................................................................. 12
Chapter 3 –Installation............................................................................................................................................................... 13
3.1 Selecting A Location........................................................................................................................................................... 13
3.1.1 Lifting Instructions .......................................................................................................................................................... 13
3.2 Mounting ............................................................................................................................................................................. 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 ...................................................................................................................................................................... 15
Chapter 4 –Setup & Configuration............................................................................................................................................. 17
4.1 User Checklist ..................................................................................................................................................................... 17
Chapter 5 –Basic Operation....................................................................................................................................................... 18
5.1 Using the Keypad................................................................................................................................................................ 18
5.2 Alarm & Fault Screens ........................................................................................................................................................ 18
5.3 Menu Overview CL1/Cl2 ..................................................................................................................................................... 20
5.4 Power-on Initialization ....................................................................................................................................................... 20
5.5 Main Menu........................................................................................................................................................................... 21
5.5.1 Start Analysis................................................................................................................................................................... 21
5.5.2 System Faults .................................................................................................................................................................. 22
5.5.3 Gas Alarms....................................................................................................................................................................... 22

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CL1 & CL2 Manual
5.5.4 Gate & Tape...................................................................................................................................................................... 23
5.5.5 Alarm Levels..................................................................................................................................................................... 23
5.5.6 Event & Alarm History...................................................................................................................................................... 23
5.5.7 Test Alarms ...................................................................................................................................................................... 23
5.6 Setup Menu ......................................................................................................................................................................... 24
5.6.1 Main Menu ....................................................................................................................................................................... 24
5.6.2 Tape Saver ....................................................................................................................................................................... 24
5.6.3 Latching Relays ............................................................................................................................................................... 25
5.6.4 Enable Pumps .................................................................................................................................................................. 26
5.6.5 Enable Points ................................................................................................................................................................... 26
5.6.6 Energized Alarm Relays................................................................................................................................................... 26
5.6.7 Idle Timeout ..................................................................................................................................................................... 26
5.6.8 Date and Time.................................................................................................................................................................. 27
5.6.9 Test 4-20mA .................................................................................................................................................................... 27
5.6.10 Select Gas ...................................................................................................................................................................... 27
5.6.11 Conc. Logging (Concentration Logging)...................................................................................................................... 27
5.7 Service Menu....................................................................................................................................................................... 28
5.7.1 Voltage Cal ....................................................................................................................................................................... 28
5.7.2 Optic Calibration .............................................................................................................................................................. 28
5.7.3 Passwords........................................................................................................................................................................ 28
5.7.4 Optic Config...................................................................................................................................................................... 28
5.7.5 Status ............................................................................................................................................................................... 28
5.7.6 Clear History..................................................................................................................................................................... 29
5.7.7 Configuration ................................................................................................................................................................... 29
Chapter 6 –Maintenance............................................................................................................................................................ 30
6.1 Maintenance Door Access ................................................................................................................................................. 30
6.2 Service Door Access........................................................................................................................................................... 30
6.3 ChemLogic®Paper Tape .................................................................................................................................................... 31
6.4 End-of-Line Particulate Filters .......................................................................................................................................... 33
6.5 Flow Adjustment ................................................................................................................................................................. 34
6.6 Micro Secure Digital (SD) Card Replacement................................................................................................................... 34
6.7 Fuse Replacement .............................................................................................................................................................. 34
6.8 Grease Application.............................................................................................................................................................. 35
Chapter 7 –Service & Support.................................................................................................................................................... 36
Appendix A –Accessories & Spare Parts .................................................................................................................................. 37
Appendix B –I/O Connection Detail........................................................................................................................................... 40
Appendix C –Technical Specifications...................................................................................................................................... 41
Appendix D –System Event Messages...................................................................................................................................... 42
Appendix E –Gas Specifications................................................................................................................................................ 45
Appendix F –Removable Media ................................................................................................................................................. 48

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CL1 & CL2 Manual
F.1 Concentration Log Files ..................................................................................................................................................... 48
F.2 Event Log Files .................................................................................................................................................................... 48
F.3 Formatting Micro SD Disks ................................................................................................................................................ 49
F.3 SD Card Status Menu Item................................................................................................................................................. 51
Appendix G –ChemLogic®Cassettes ........................................................................................................................................ 52
Appendix H –Advanced Optics Cleaning Procedure ................................................................................................................ 53
H.1 Optic Orifice Cleaning ........................................................................................................................................................ 55
Appendix I –Additional Options ................................................................................................................................................. 56
I.1 Pressure Check Disable Mode ............................................................................................................................................ 56
I.2 Optics Auto Calibration ....................................................................................................................................................... 56
I.3 Maintenance Relay .............................................................................................................................................................. 56
I.4 Z-Purge Enclosures with Vortex (A/C) Coolers ................................................................................................................. 57
I.5 New Light Option ................................................................................................................................................................. 59

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CL1 & CL2 Manual
Chapter 1 –Overview
1.1 Introduction
WARNING:
Operation of the ChemLogic® 1 & 2 continuous gas detection system without a manual in the native language
in its country of operation is illegal. A translated copy of the manual should be requested immediately from
DOD Technologies and before installation of the device. Failure to do so may result in severe injury.
Contact:
Phone: [phone]
email: [e-mail]
The ChemLogic®1 & 2 continuous gas detection systems should be used exclusively for the quick detection
of toxic, corrosive, and asphyxiant gases for process measurement and personnel safety purposes. Failure to
comply with the intended purpose of the device may result in injury or death.
The DOD Technologies ChemLogic®1 & 2 continuously monitors a single or double location (called a point)
for toxic and corrosive gas. It responds to gas that exceeds 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/CL2 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/CL2 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 be leaking.
The CL1/CL2 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/CL2 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/CL2.
1.3 Flow Connections
Flow connections consist of “quick-connect” ports on the bottom and side of the CL1/CL2. There is one inlet
and one exhaust outlet.

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CL1 & CL2 Manual
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/CL2
provides all electrical connections for the outputs and remote reset.
NOTE: Maximum Branch-Circuit Rating = 20 Amperes
1.5 Theory of Operation
The sample flow is diverted across the ChemLogic® Tape. The ChemLogic®1 & 2 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 & 2. The ChemLogic®1 & 2 will then report an appropriate gas concentration reading
and/or a gas alarm.

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CL1 & CL2 Manual
Chapter 2 –Features
2.1 External Layout
Figure. 2.1
2.1.1 Warning Labels, Descriptions, & Danger Zones
The below table references all warning labels and their meanings that may be encountered while
operating and servicing the ChemLogic®1 and 2 continuous gas detection equipment.
WARNING:
Hot Surface. This surface will be hot to touch and may cause injury. Please avoid or
take 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 read operators manual for all instruction for this machine. If manual is not in
country’s native language, requested updated manual before use of equipment.
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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CL1 & CL2 Manual
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.
2.1.2 ChemLogic®1 & 2 Danger Zones
Please be aware of the following danger zones on the ChemLogic®1 and 2 continuous gas detection
equipment. Each zone contains warning labels for operator safety. Label meanings/descriptions can
be found in the above table.
A
WARNING:
This danger zone is located on the right side of the unit. It is the
warning for electrical shock in the following danger zone C.
B
WARNING:
This danger zone is located on the gate assembly. During
operation, operators could pinch fingers if not aware of
hand placement.
C
WARNING:
This danger zone is in the interior of the unit after zone A.
Operators could experience electric shock here if caution is
not exercised.
2.1.3 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.