DOD CL96 Operating manual

DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-ITD-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
CL96 Gas Detection System
Technical Service Manual
Revision 16.11

DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-ITD-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
Table of Contents
Preventative Maintenance.......................................................................................................................... 1
Optics System: ........................................................................................................................................ 1
DAC verification: ................................................................................................................................. 1
Background Verification:..................................................................................................................... 2
Flow System:............................................................................................................................................... 3
Pressure Sensor Calibration: ............................................................................................................... 3
System Flow Balance:.......................................................................................................................... 4
Point Flow Check with Flowmeter: ..................................................................................................... 5
Exhaust Integrity Check:...................................................................................................................... 5
Tape advance system:................................................................................................................................. 6
Advance Distance Verification: ........................................................................................................... 6
Micro Switch Verification:................................................................................................................... 7
Lubricating Gate Assembly:................................................................................................................. 8
Power verification:...................................................................................................................................... 8
DC Voltage Verification Procedure:..................................................................................................... 8
Vibration Damage and Wire Inspection:................................................................................................... 11
Vibration Damage Inspection Procedure: ......................................................................................... 11
Wire Inspection Procedure: .............................................................................................................. 11
Faults & Troubleshooting:......................................................................................................................... 12
Optic Cleaning Procedure: ................................................................................................................ 16
Optic System Troubleshooting Procedure: ....................................................................................... 20
Power Verification Procedure:.......................................................................................................... 21
Communication Verification: ............................................................................................................ 23
Gate Fault Procedure:....................................................................................................................... 25
Flow Check Procedure: ..................................................................................................................... 27
Flow Communication Verification Procedure: .................................................................................. 27
Flow Path Verification Procedure: .................................................................................................... 30
I/O Verification Procedure: ............................................................................................................... 31
Hardware Replacement: ........................................................................................................................... 34

DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-ITD-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
Optic Block Replacement: ................................................................................................................. 34
Pump Replacement:.......................................................................................................................... 37
Appendices ............................................................................................................................................... 39
Appendix A: Control Wiring .................................................................................................................. 39
Appendix B: Pump Panel Wiring ........................................................................................................... 40
Appendix C: Analyzer Wiring................................................................................................................. 41

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DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
Preventative Maintenance
Optics System:
DAC verification:
The optic system is self-adjusting and will calibrate itself during analysis. A clean optic channel will have
a DAC value between 60 and 140. The DAC values for all points can be found by following these steps.
1. Enter Setup Menu
2. Enter Factory Menu
3. Enter password “1225”
4. Select the System tab
5. Press the DAC button for any active analyzer (see image below )

Page 2of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
If there is a DAC value outside of the suggested range, verify the Chemlogic cassette is installed correctly
and press calibrate. If the DAC is still outside the suggested range refer to the CL96 Optic Cleaning
Procedure.
Background Verification:
The background value for each point can be found in the system screen by following the steps below. If
any of the background values are not between 2600 and 3300 the optics should be calibrated by
pressing the calibrate button.
1. Enter Setup menu
2. Enter Factory menu
3. Enter password “1225”
4. Select the System tab
5. Press the ADC button for any active analyzer (see image below)

Page 3of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
Flow System:
Pressure Sensor Calibration:
The flow system is monitored internally using one pressure sensor per point. Each pressure sensor has a
voltage offset which represents atmospheric pressure when the pumps are turned off. The
recommended range for the voltage offset per point is 1000-1400. The voltage offsets can be found by
following these steps:
1. Enter Setup Menu
2. Enter Factory Menu
3. Enter password “1225”
4. Select the System tab
5. Press the Offsets button for any active analyzer (see image below)
If there is an offset voltage outside of the suggested range remove the sample line and press Set Offsets.
If the offset is still outside the suggested range refer to the CL96 Flow Troubleshooting Section.

Page 4of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
System Flow Balance:
After all voltage offsets are verified to be within range, the entire system can now be flow balanced. To
flow balance the system follow these steps:
1. Enter the Setup Menu
2. Select the Adjust Flow tab
3. Select the point grouping that needs to be balanced (see image below)
4. Any point that is not balanced to the black line in the green region should be adjusted.
5. Locate the Point Arrangement Label on the top of the Cl96 enclosure near the inlet manifold.
6. Use the black knobs to adjust and balance inlet flow on each point.

Page 5of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
Point Flow Check with Flowmeter:
After the flow system is balanced an additional flow check can be done at the inlet of each point using a
flowmeter. Each point should be sampling at a flow rate between 1.2 and 1.5 LPM (liters per minute)
and this can be measured with a 0-5 LPM flowmeter as show in the center below.
Exhaust Integrity Check:
The exhaust line for each pump should be checked periodically to verify the unit is exhausting correctly.
This check can be done by going to the Adjust Flow screen in the Setup Menu. In this screen each pump
can be turned on individually by selecting the points that are related to that pump. (See chart below to
determine which points are related to which points.) When the pump is turned on in this screen all
related point should be balanced near the black line in the green region. Now locate the exhaust port for
the related pump on the side of the CL96 (see image below) and plug it. When the exhaust port is
plugged, all points should drop to the bottom of the scale in the yellow region. If the onscreen
flowmeter does not drop to the bottom of the scale remove the CL96 rear panel and check for leaks
between the exhaust port on the side of the cabinet and the exhaust port on the related pump.

Page 6of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
Pump
Pump 1
Pump 2
Pump 3
Pump 4
Pump 5
Pump 6
Related
Points
A 1-16
A 17-32
B 1-16
B 17-32
C 1-16
C 17-32
Tape advance system:
Advance Distance Verification:
The distance of each tape advance should be greater than .4 in. and less than .5 in. This can be verified
by following these steps:
1. Go to the Main Menu
2. Press the Load Tape tab
3. Mark the tape after the optic blocks on the left hand side. (See picture below)
4. Advance the tape by pressing Open Gate then Close Gate

Page 7of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services
5. Measure the distance the tape advanced past the previous mark
If the tape advance distance is not within the suggested range refer to the Tape Advance Adjustment
procedure.
Micro Switch Verification:
Each CL96 analyzer uses (2) micro switches (see images below) in order to identify the position of the
gate during a tape advance. Each micro switch is held in place by (2) Philips head screws. If these screws
become loose it could affect the analyzers ability to complete a successful tape advance. Verifying
tightness of these screws can be done one time per year at the same time the gate assembly is
lubricated.