DOD Technologies ChemLogic 4 User manual

ChemLogic®4 & 8
Continuous Gas Monitor User Manual

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CL4 & CL8 Manual
©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: CL4/CL8
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
1.6 Time Weighted Average (TWA) ............................................................................................................................................ 8
Chapter 2 –Features ..................................................................................................................................................................... 9
2.1 External Layout ..................................................................................................................................................................... 9
2.1.1 Warning Labels, Descriptions, & Danger Zones .............................................................................................................. 9
2.1.2 ChemLogic 4 & 8 Danger Zones ..................................................................................................................................... 10
2.1.3 Status Lamp (OPTIONAL) ............................................................................................................................................... 11
2.1.4 Output Wiring Knockouts ................................................................................................................................................ 11
2.1.5 Touch Screen Display...................................................................................................................................................... 11
2.1.6 Keyed Service Door Access ............................................................................................................................................ 11
2.1.7 A/C Power & Switch......................................................................................................................................................... 11
2.1.8 Flow Adjustment.............................................................................................................................................................. 11
2.1.9 ChemLogic Paper Tape ................................................................................................................................................... 11
2.1.10 Maintenance door.......................................................................................................................................................... 11
2.1.11 Take-up reel................................................................................................................................................................... 12
2.1.12 Tubing Connections ...................................................................................................................................................... 12
2.2 Maintenance area ............................................................................................................................................................... 12
2.3 Internal Layout –Service area........................................................................................................................................... 12
2.4 Password Security.............................................................................................................................................................. 13
2.5 USB Memory Stick .............................................................................................................................................................. 14
Chapter 3 –Installation............................................................................................................................................................... 15
3.1 Selecting a location ............................................................................................................................................................ 15
3.1.1 Lifting Instructions .......................................................................................................................................................... 15
3.2 Mounting ............................................................................................................................................................................. 17
3.3 Sample Tubing .................................................................................................................................................................... 19
3.3.1 Sample Manifold Relocation........................................................................................................................................... 19
3.3.2 End of line particulate filters ........................................................................................................................................... 19
3.4 Exhaust tubing .................................................................................................................................................................... 20
3.5 A/C Power............................................................................................................................................................................ 20
3.6 Output Wiring ...................................................................................................................................................................... 20

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3.6.1 Standard Output Relay Module Wiring........................................................................................................................... 20
3.6.2 Optional 4 to 20ma Output Module Wiring .................................................................................................................... 22
3.6.3 Optional 8 Point Relay Module (Item #2-500-012)....................................................................................................... 22
Chapter 4 - Setup & Configuration.............................................................................................................................................. 23
4.1 Set system date and time .................................................................................................................................................. 23
4.2 Gas Selection ...................................................................................................................................................................... 23
4.3 Alarm Settings..................................................................................................................................................................... 23
4.4 Output Relays...................................................................................................................................................................... 23
4.5 Concentration Logging....................................................................................................................................................... 23
4.6 Install new tape................................................................................................................................................................... 23
4.7 USB Memory Stick .............................................................................................................................................................. 24
4.8 Setup Complete................................................................................................................................................................... 24
Chapter 5 –Basic Operation....................................................................................................................................................... 25
CL4/CL8 Menu Overview .......................................................................................................................................................... 25
5.1 Initialization......................................................................................................................................................................... 25
5.2 Setup / Main Menu ............................................................................................................................................................. 26
5.2.1 Gas & Alarm Settings Menu ............................................................................................................................................ 27
5.2.2 Set Date/Time .................................................................................................................................................................. 27
5.2.3 Load Tape......................................................................................................................................................................... 28
29
5.2.4 Flow Adjustment.............................................................................................................................................................. 29
5.2.5 Calibration Factors .......................................................................................................................................................... 30
5.2.6 Set & Test Outputs........................................................................................................................................................... 31
5.2.7 Factory Settings............................................................................................................................................................... 32
5.2.8 Event History.................................................................................................................................................................... 32
5.3 Concentration Log .............................................................................................................................................................. 33
5.3.1 Concentration Configuration .......................................................................................................................................... 33
5.4 Analysis Mode..................................................................................................................................................................... 34
5.5.1 Point Detail screen .......................................................................................................................................................... 35
5.5 USB Memory Stick log........................................................................................................................................................ 35
5.6 Time Weighted Average (TWA) .......................................................................................................................................... 36
Chapter 6 –Maintenance............................................................................................................................................................ 38
6.1 Maintenance Door Access ................................................................................................................................................. 38
6.2 Service Door Access........................................................................................................................................................... 38
6.3 ChemLogic Paper tape ....................................................................................................................................................... 38
ChemLogic Paper Tape Installation Procedure ...................................................................................................................... 39
6.4 End of line particulate filters .............................................................................................................................................. 40
6.5 Flow adjustment ................................................................................................................................................................. 41

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6.6 USB Memory Stick replacement........................................................................................................................................ 41
6.7 Apply grease periodically ................................................................................................................................................... 42
6.8 Fuse Replacement .............................................................................................................................................................. 42
Chapter 7 –Service & Support.................................................................................................................................................... 43
Appendix A –Accessories / Cassettes ...................................................................................................................................... 44
Appendix B –I/O Connection Detail ........................................................................................................................................... 46
B.1 Standard Output Relay Module ......................................................................................................................................... 46
B.2 4 to 20mA Module (2 Points per Module) (PN: 2-500-011) ...................................................................................... 47
B.2.1 4 to 20mA Module (4 Points per Module) (PN: 2-500-011) ................................................................................... 48
B.3 8-Point Module (PN: 2-500-012) ...................................................................................................................................... 49
B.4 Optional Mechanical Relays .............................................................................................................................................. 50
B.4.1 Optional Mechanical Relay Wiring ................................................................................................................................. 51
B.5 OPC Interface (PN: 2-500-501) ......................................................................................................................................... 53
Appendix C –System Specifications ......................................................................................................................................... 54
Appendix D –System Event Messages...................................................................................................................................... 55
Appendix E –Gas Specifications................................................................................................................................................ 57
Appendix F –USB Memory Stick Data....................................................................................................................................... 59
F.1 Alarm & Event files (ZG*.CSV)............................................................................................................................................ 59
F.2 TWA Data Logs (TYYMMDD.CSV) ..................................................................................................................................... 60
F.3 Concentration Log Files (ZL*.CSV).................................................................................................................................... 60
F.4 Config File............................................................................................................................................................................ 61
Appendix G –ChemLogic Cassettes .......................................................................................................................................... 62
Appendix H –Optic Block Cleaning Procedure ......................................................................................................................... 63
H.1 Basic Optics Cleaning ........................................................................................................................................................ 63
H.2 Advanced Optics Cleaning................................................................................................................................................. 64

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Chapter 1 –Overview
1.1 Introduction
WARNING:
Operation of the ChemLogic 8 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 4 (CL4) & 8 (CL8) 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 4 (CL4) ChemLogic 8 (CL8) simultaneously monitors eight locations
(called points) for toxic and corrosive gases. It responds to gases that exceed a programmed alarm level by:
• Triggering visual alarms that warn of high or low concentrations
• Triggering relays or activating analog outputs to external devices
• Displaying the point number, gas type, and gas concentration
• Recording the alarm information and storing it in memory
The CL/4CL8 triggers relays for each individual point for two levels of gas concentrations. These
programmable limits are factory-set at 1 TLV and 2 TLV for their respective gases.
Each point may be up to 300 feet (91.44 m) from the CL4/CL8 location. This allows operators to monitor gas
concentrations in an area removed from the location where gas may actually be leaking.
The CL4/CL8 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 CL4/CL8 uses DOD Technologies ChemLogic paper tape technology for fast and accurate gas detection.
1.2 Sampling and Monitoring
The system draws sample flow simultaneously from all eight points. Part of the sample flow is diverted
across the ChemLogic tape. All 4/8 channels exhaust through a single port. The ChemLogic 4/8 continuous
gas detection system operates at a noise level below 70 dB(A) and does not require hearing protection for
operation or work within close proximity. Workplace environment outside the ChemLogic 4/8 system may still
require hearing protection. Please consult your safety officer for your recommended safety protocols.
1.3 Flow Connections
Flow connections consist of “quick-connect” ports on the top or side of the CL4/CL8 UNIT. There are eight
inlets, one for each monitored point, and an exhaust outlet.

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1.4 Electrical Connections
“Knockout panels” for external electrical connections are provided on the top or right side of the CL4/CL8.
The covers are exchangeable to provide top or right-side flexibility.
1.5 Theory of operation
The system draws sample flow simultaneously from all four/eight points. Part of the sample flow is diverted
across the ChemLogic Tape. The ChemLogic 4/8 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 4/8. The ChemLogic 4/8 will then
report an appropriate gas concentration reading and/or a gas alarm.
1.6 Time Weighted Average (TWA)
During analysis the CL4/CL8 stores the TWA information every 8 hours* (referred to as a ‘cycle’). The
system retains the 5 most recent cycles in memory and will save all cycles to the CUSB Memory Stick –if
installed. The number of cycles capable of being stored on the USB Memory Stick is only limited by the size
of the USB Memory Stick.
*NOTE: If analysis is stopped by the operator or due to any other factor (critical
service fault, power interruption, etc.), the TWA information is saved as a
separate cycle regardless of how much time has elapsed since the cycle started.

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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 4 and 8 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.
Output Wiring Knockouts
Keyed Service Door Handle
A/C Power & Switch
Flow adjustment knobs
ChemLogic Tape
Maintenance Door
Take-up reel
4 color status lamp and
audible alarm (Optional)
Flow tubing & exhaust
quick connect system
Touch Screen LCD Display

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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 4 & 8 Danger Zones
Please be aware of the following danger zones on the ChemLogic 4 and 8 continuous gas detection
equipment. Each zone contains warning labels for operator safety. Label meanings/descriptions can be found
in the above table
A
This danger zone is in the service access point of the unit. Users
should be aware of hot surfaces and electrical shock.
B
This danger zone is located on the gate assembly. During
operation, operators could pinch fingers if not aware of hand
placement.
C
This danger zone is located on the right exterior of the unit. This
area warns of electrical shock areas within the service door of the
machine.

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2.1.3 Status Lamp (OPTIONAL)
The optional status lamp consists of 4 colored lights –Red, Orange, Blue, and Green along with an audible
alarm. See Appendix A for ordering information.
2.1.4 Output Wiring Knockouts
There are two knockouts available for output wiring located on the top panel near the right side and on the
right-side panel near the top.
2.1.5 Touch Screen Display
The CL8 uses a full color touch panel LCD display. All menus and data entry are accomplished by touching
the appropriate area of the screen –see Chapter 5 “Basic Operation”.
2.1.6 Keyed Service Door Access
The door uses a key lock to restrict internal access. See section 2.3 for detailed information on the service
area.
2.1.7 A/C Power & Switch
A/C power is connected on the right-side panel with a standard cable. The on/off power switch is located
adjacent to the power cable connection.
2.1.8 Flow Adjustment
Flow adjustments for all 4/8 points are located on the front panel. Refer to section 5.2.d regarding flow
adjustment.
2.1.9 ChemLogic Paper Tape
ChemLogic paper tapes are accessed by opening the maintenance door. Refer to section 6.3 regarding tape
installation/replacement.
2.1.10 Maintenance door
The maintenance door allows easy access to the ChemLogic tape for installation and replacement.
IMPORTANT: The maintenance door should remain closed and latched except
when changing the ChemLogic tape. Do not open the door while in Analysis
Mode.

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2.1.11 Take-up reel
An empty take-up reel is inserted at the time of ChemLogic tape installation (see section 6.3). During
installation the previous take-up reel which is full is removed from CL4/CL8 and discarded. The previous
ChemLogic tape reel which is now empty should then be used as the next take-up reel.
2.1.12 Tubing Connections
Sample tubing and exhaust use a quick connection system for simple installation. The connections may be
made on either the top or left side of the CL4/CL8. See section 3.3 for information on connecting the sample
and exhaust tubing. See also Appendix C for essential information on transport times for gas from sampling
point to the CL4/CL8.
2.2 Maintenance area
The maintenance area allows easy access for changing ChemLogic tape in the CL4/CL8. Figure 2.2 shows
the internal layout with the access panel open. See section 3.5 for tape installation.
Figure 2.2
2.3 Internal Layout –Service area
Internal access to the CL4/CL8 for installation and service uses the keyed handle located on the right side of
the front panel. Figure 2.3 shows the internal layout of the CL4/CL8 with the service door open.
IMPORTANT: End of line filters are required at all times on each channel –see
Section 6.2.

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The door should be opened by trained service personnel (See section 6.2 )
Figure 2.3
2.4 Password Security
Access to many of the features is controlled through password protection which is entered through the
screen displayed in figure 2.4.
Figure 2.4
DANGER: Turn off the unit and disconnect unplug A/C power to the
unit before opening the Service Door.
Inside w/Service Door open
Back of Service Door
(OPTIONAL) 4-20ma
output
Output Connection
Block
USB Memory Stick Access
Pump
Power Supply

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Whenever someone attempts to access a screen that is password protected, the screen shown in figure 2.2
will appear (see important note below). Several of the setup & configuration screens of the CL4/CL8 require
entry of an administrative password. Factory service screens require entry of a service password - see
section 7.
NOTE:The Administrative Password is included on the first page of this manual. It is suggested that you
remove the page and keep in a safe and secure place. If you forget or lose your password please contact
DOD Technologies, INC. See Chapter 7 for contact information.
2.5 USB Memory Stick
The CL4/CL8 uses a USB Memory Stick to store historical information including concentration logging, event
history, configuration information, and TWA data. The use of higher speed USB Memory Stick (2x, etc.) may
not be compatible with the CL4/CL8. USB Memory Sticks may be purchased through DOD Technologies –see
Appendix A.
IMPORTANT: Once a password is entered it remains active for 2 minutes after
entry so that it does not need to be repeatedly entered when switching between
screens. Please remember that anyone using the touch screen may access
restricted screen locations during this time if the machine is left unattended.

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Chapter 3 –Installation
3.1 Selecting a location
The CL4/CL8 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 300 ft. Using the shortest possible sample line length will reduce
transport times and increase the response time of the CL4/CL8.
(see Appendix C)
•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 CL4/CL8 requires stable temperature and humidity levels within range to operate properly.
Recommendations
Do not place in a location which will expose the CL4/CL8 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:
1. 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!
Get as close to the load as possible
•Walk over to the load –don’t stand still and reach for it

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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.

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3.2 Mounting
Figure 3.1
Front

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Figure 3.2
Figure 3.4
Top
Right
Side

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Refer to figure 3.1 for dimensional requirements for wall mount. Be sure the CL4/CL8 is properly secured to
the wall.
3.3 Sample Tubing
Sample tubing may be connected to the CL4/CL8 on the top or left side of the CL4/CL8 (see section 3.3.1). All
sample tubes are 1/4” OD x 3/16” ID Teflon FEP (300 ft max length) which may be purchased from DOD
Technologies, INC (See Appendix A).
Fully depress each sample tube into the proper hole when attaching. To detach the tube, push on the collet
and pull the tubing out
3.3.1 Sample Manifold Relocation
The quick connect system used to attach sample tubing and exhaust may be located on the top or left side of
the machine. To move the manifold, Follow the procedures in section 6.2 to open the service door.
•Remove the four (4) mounting screws shown in figure 3.5 to detach the manifold.
•Remove the 4 lock nuts holding the cover plate over the unused manifold opening
•Remove the cover plate
•Align the manifold inside the CL4/CL8 with the holes in the new position
•Replace the screws holding the manifold in place and tighten accordingly.
•Replace the cover plate over the unused opening and secure with the four lock nuts.
Figure 3.5
Sample tubing may be purchased from DOD technologies (see appendix A)
3.3.2 End of line particulate filters
End of line particulate filters must be installed on all 4/8 sample lines at all times to prevent damage to the
unit. Unused lines must either be plugged or have a filter installed. Filters require regular maintenance –see
chapter 6.
IMPORTANT: All sample tubing used with the CL4/CL8 must be 1/4”OD x 3/16”
ID FEP Teflon. Use of any other tubing may damage the CL4/CL8 and/or cause
inaccurate gas concentration readings.

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End of line particulate filters may be purchased from DOD technologies (see appendix A)
3.4 Exhaust tubing
The exhaust line must be 3/8” OD x 1/4” 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 CL4/CL8. Longer cords are available
from most electrical supply stores.
3.6 Output Wiring
Figure 3.2 details the connection method for both the standard relay output module and the optional 4 to 20
ma modules.
See Appendix B for a listing of output module connections.
3.6.1 Standard Output Relay Module Wiring
The standard output module requires an external 24V supply connected to V1+/- and V2+/- (see Appendix B).
Outputs 0-15 are powered through V1 while outputs 16-31 are powered through V2. Each output can handle
up to 0.2 Amps with a total maximum current of 1.6Amps to each group of 16 outputs at any time. See figure
3.6 and 3.7 for information on wiring the CL4/CL8 standard relay outputs.
IMPORTANT: All points require filtration to prevent dust accumulation in tubing and
internal damage to the CL4/CL8. Dust that collects in the tubing or the internal
system may cause sample loss and inaccurate gas concentration readings.
Wiring knockouts on sides of
cabinet
Service
Door
Open
DOD 4 to 20ma Module 1
DOD 4 to 20ma Module 2
DOD Output Relay
Module
Pump