DOD Technologies ChemLogic 1 User manual

ChemLogic®1 & 2
Continuous Gas Monitor User Manual

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

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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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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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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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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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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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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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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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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.

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IMPORTANT: The maintenance door should remain closed and latched except when changing the
ChemLogic®tape.
2.1.4 Keypad & Display
The CL1/CL2 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.
2.1.5 ChemLogic®Tape and Take-up Reel
ChemLogic®paper tapes are accessed by opening the maintenance door. Refer to chapter 6 regarding tape
installation/replacement.
2.1.6 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/CL2. 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: End of line filters are required. See section 6.4.
2.1.7 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.
2.1.8 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/CL2. Figure 2.2 shows
the internal layout with the access panel open. See section 6.3 for tape installation.
Figure 2.2

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2.3 Internal Layout –Service Area
Internal access to the CL1/CL2 for service uses the latches located on the right side of the front panel. Figure
2.3 shows the internal layout of the CL1/CL2 with the service door open.
The door should be opened by trained service personnel (See section 6.2)
Figure 2.3
DANGER: Turn off the unit, disconnect A/C power and unplug the 14 pin I/O connector on the
side of the unit (if installed) before opening the service door.
2.4 Micro Secure Digital Card (SD Card)
The CL1/CL2 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.
Back of Service Door
Inside of Service Door
SD Card Access Door
Output Connection Block
Power Supply
Pumps

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Chapter 3 –Installation
3.1 Selecting A Location
The CL1/CL2 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 length.
•Using the shortest possible sample line length will reduce transport times and increase the response
time of the CL1/CL2.
•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/CL2 requires stable temperature and humidity levels within range to operate properly (see
Appendix C)
NOTE:Options are available for heating or cooling the CL1/CL2 –Contact DOD Technologies for details.
RECOMMENDATIONS:
Do not place in a location which will expose the CL1/CL2 to moisture, dust, corrosive gas, or any unusual
environmental conditions which could damage the unit and/or cause it to operate inaccurately.
3.1.1 Lifting Instructions
It is recommended that installation of this unit requires the help of 3 individuals. Two individuals should lift
the unit into its desired location while the third person secures the device into a mounted position. If the
device must be manually handled, follow the following steps each time:
Size up the Load
• Check if the weight of the object is listed on it
• If not, push, pull, gently kick or rock the object to be moved before you attempt to move it – get a feel for its
weight, size and shape
• Check whether the weight is evenly distributed
• Recognize what your own limits are and stick to these limits
Ensure the area is clear
• Work out where the load is going
• Ensure that your intended pathway is clear and free of obstacles
• Make sure that your vision will not be blocked when moving large objects
Position your feet correctly
• Place your feet a comfortable distance apart (shoulder width). A broader base of support increases stability.
With a narrow base of support with your feet too close together, you are more likely to lose your balance.
• Point your feet in the direction that you intend to travel
• Always turn with your feet, not your hips or shoulders. Never twist as you move or go to lift!

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Get as close to the load as possible
• Walk over to the load – don’t stand still and reach for it
Maintain the normal curves in your spine You need to try and work in your power zone –above your knees
and below the shoulders
• Keep the back straight and the head looking up
• Half bend the knees and use your leg muscles
• Bend forward at the waist
• Stick your bottom out
• Bend your back as little as possible
• Keep your head looking up, not down
• Put weight down through your heels, not the toes
Use the correct grip
• Have a firm grip by using the palms and the base of the fingers
• Don’t just use your fingertips as this can cause strain on the hands,
wrists and forearms
Lift Smoothly
• Grip the load firmly and hold it close to your body.
• Keep the heaviest side closest to your body
• ‘Brace’ (tighten) your stomach muscles. Remember to breathe out when
you lift. However, remember that bracing the stomach muscles does
not mean ‘holding your breath’
• Thrust with the legs - Use the leg muscles to move the load (quadriceps
and gluteal muscles). They are much bigger and stronger than the back
muscles
• Complete the movement smoothly and without jerkiness
3.2 Mounting
Refer to figure 3.1 for dimensional requirements for wall mount. Be sure the CL1/CL2 is properly secured to
the wall.
Figure 3.1

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3.3 Sample Tubing
Sample tubing connects to the CL1/CL2 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.
IMPORTANT:Sample tubing used with the CL1/CL2 must be 1/4” OD x 1/8” ID FEP. Use of any other tubing
may damage the CL1/CL2 and/or cause inaccurate gas concentration readings.
3.3.1 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)
IMPORTANT:The CL1/CL2 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.
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/CL2. 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/CL2 to increase precision. When not in analysis the CL1/CL2
will output the 2ma calibrated value. There is a maximum of 500-ohm load impedance on the 4-20ma circuit.
See Appendix B for a listing of output module connections.
Gas Inlet on Bottom of CL1 / CL2

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DANGER: Turn off the unit, disconnect A/C power and unplug the 14 pin I/O connector on the
side of the unit (if installed) before any wiring modifications.

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Chapter 4 –Setup & Configuration
4.1 User Checklist
Follow this checklist to configure the CL1/CL2 for first time operation or after a software upgrade.
___ Set passwords (section 5.6.3)
___ Set system date and time (section 5.5.7)
___ Gas selection (section 5.5.9)
Appendix E contains the specifications for each gas.
___ Alarm level settings (section 5.4.5)
___ Latching relays (section 5.5.3)
___ Energized Relays (section 5.5.5)
___ Idle Timeout (section 5.5.6)
___ Testing Contacts (section 5.4.7)
___ Adjustment of 4-20 ma (section 5.5.8)
___ Install new ChemLogic tape (section 6.3)
___ Install removable media (section 6.6)
___ Format removable media (Appendix F.3)
___ Tape Saver Mode (TSM section 5.5.)
___ Grease the Gate Cam (section 6.7)
___ Verify Sample Inlet flow ( post software upgrade only )
Setup complete - Ready for monitoring.

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Chapter 5 –Basic Operation
5.1 Using the Keypad
The CL1/CL2 is controlled using the keypad located around the display. All the display screens are accessed
through a simple menu system.
NOTE 1) The arrow keys located under the screen are used for two purposes.
1. 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.
2. To select among multiple data fields on some of the screens for editing.
NOTE 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.
NOTE 3) When numeric entry is required on any screen the following procedure is used.
Use the arrow keys below the screen to select which field to edit. The currently selected box
will have a dashed line around it.
1Press the <ENTER> key first
2Use the numeric/function keys to enter the value
3Also note the up arrow may be used for +/- and the down arrow may be used for the decimal point when
necessary.
4Press the <ENTER> key again to complete the entry
NOTE: The <F1> key is used to exit analysis and return to the Main Menu.
5.2 Alarm & Fault Screens
Three types of messages used in the CL1/CL2:
Alarm messages (level 1 and level 2)
System faults (critical faults that terminate and/or prevent analysis)
Event messages (warnings, non-critical faults, and various events)
Note 2
Note 1
Note 3

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See Appendix D for a description of each message. The history log always keeps the most recent 128
messages of any type in memory. All three types of messages are also logged to the Micro SD card if
present.
Various screens are used in the CL1/CL2 to show some or all 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 like 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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5.3 Menu Overview CL1/Cl2
Note 1: The setup menu is not password protected by default.
Note 2: The service menu is password protected by default.
Passwords can be changed/cleared in the Password screen on the Service Menu (Section 5.6.3)
5.4 Power-on Initialization
When the CL1/CL2 is powered on it will begin with an initialization screen (figure 5.4) which is followed by the
restart screen (figure 5.5).
If the operator touches the <MENU> soft key before the timer reaches 0 the Main Menu (section 5.5.1 )
appears otherwise after a timeout the system will automatically start analysis (section 5.4.1)
Figure 5.4
Figure 5.5
Start Analysis
System Faults
Gas Alarms
Gate & Tape
Alarm Levels
Fault/Alarm History
Test Alarms
Setup Menu
Service Menu
Main Menu
Voltage Cal
Optic Calib.
Passwords
Status
Optic Config
Clear History
Offsets
Configuration
Test 4-20ma
Main Menu (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
SD Card
Setup Menu (5.5)
See Note 1
Automatic