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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CL4 & CL8 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: 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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CL4 & CL8 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
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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CL4 & CL8 Manual
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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CL4 & CL8 Manual
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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CL4 & CL8 Manual
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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CL4 & CL8 Manual
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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CL4 & CL8 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 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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CL4 & CL8 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 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.