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

Page 1of 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
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
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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
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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]
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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]
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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
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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]
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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.

Page 8of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
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Lubricating Gate Assembly:
Each analyzer has two gate assemblies located directly below an installed Chemlogic cassette. For the
gate assembly to work efficiently, the cam (see image below) attached to the motor must be lubricated
at least one time per year. This will allow the gate to open and close with as little resistance as necessary
and extend the life on the motor. The cam can be lubricated with any synthetic grease. (See image
below) Place some grease on the cam then open and close the gate several times to disperse.
Power verification:
DC Voltage Verification Procedure:
The CL96 comes with two 24VDC power supplies, one 12VDC power supply and one 5VDC power supply.
Use the chart and images below to verify the voltages are within factory specifications.

Page 9of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
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Innovative Life Safety Systems & Services
Location
DC Voltage
Both 24VDC supplies on pump panel
Greater than 24.6 –24.8 VDC
12VDC supply on pump panel
Greater than 12.5VDC
5VDC supply on pump panel
6.1VDC (max)
24VDC in control box for PC
Greater than 24.3VDC
24VDC in control box for I/O
Greater than 24.3VDC
5VDC in control box for flow system
Greater than 5.3VDC
12VDC in Control box
Greater than 12.2VDC
5VDC supply for optic blocks
Greater than 5VDC
*All power supplies can be adjusted with potentiometer
All power supply voltages should be measured from the pump panel (image below) to begin the voltage
verification test and voltages should be adjusted with the potentiometer if outside of the factory
specification.
In the Control Box there is a row of terminal blocks mounted on the rear panel (see image below). The
supply voltage for the PC and monitor can be measured at the yellow terminal block. The 12VDC supply
can be measured at the orange terminal block and the 5VDC for the flow system can be measured at the
red terminal block. The DC voltage verification should be done at the yellow terminal blocks mounted on
24V
24V
12V
5V

Page 10 of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
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the bottom panel of the control box (see image below). This 24 V supply is used to power I/O modules
located in the control box.
The supply voltage should also be checked at one optic block of each active analyzer. The voltage can
can be measured at the green and blue wire of the optic block after the cover is removed (see image
below). Because the pins are located next to each other this test should be done carfully to avoid a short
and blowing a fuse

Page 11 of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
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Vibration Damage and Wire Inspection:
Vibration Damage Inspection Procedure:
The pump panel wiring and tubing (see image below) should be checked periodically for damage caused
by vibration from the pumps. The wiring harnesses and tubing are tied away from vibration before the
CL96 leaves the factory but because the pump panel can be shifted forward the moving parts may not
always lay in the intended position. All of the wiring and pump tubing should be carefully inspected for
holes that could be cause by vibration.
Wire Inspection Procedure:
The wiring throughout the system should be visually inspected and all terminal block jumpers should be
tightened to avoid any intermittent connections. The terminal block jumpers are located in the control
box and on the pump panel on all of the terminal blocks.

Page 12 of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
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Faults & Troubleshooting:
Event
Code
Description
Possible Cause
Resolution
96112
Gas Alarm Level 1
Gas Release above Alarm Level 1.
Determine release
point
96113
Gas alarm Level 2
Gas Release above Alarm Level 2.
Determine release
point
96110
Analysis Mode
Analysis Mode
None needed
96111
TWA Cycle Complete
TWA Cycle Complete
None needed
96104
Cannot Get Background Values
Communication issue between optic
block and PC.
1. Power cycle
analyzer 2. Press
verify optics
3. Verify background
is within range in
system screen
4. Refer to optic
troubleshooting
procedure
96105
High Background
Background value is out of range.
1. Power cycle
analyzer 2. Press
verify optics
3. Verify background
is within range in
system screen
4. Refer to optic
troubleshooting
procedure
96107
PLC Comm. Error
Communication issue between PC and
PLC.
1. Power cycle the
CL96 2. If
issue reoccurs contact
DOD Technologies,
Inc.
96108
Optic Calibration Required
Optic system is unable to calibrate
automatically
1. Refer to the optic
cleaning procedure.
96109
Gas Configuration Error
System is unable to locate the files
required to detect the gas family
selected.
1. Remove the rear
panel 2. Verify the
USB thumb drive is
connected properly
3. Power cycle the
CL96

Page 13 of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
DC-MAN-CL96Servicemanual
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96116
Low Flow - Verify Tray Insertion
The flow is low for multiple points on an
analyzer.
1. Verify analyzer is
fully inserted.
2. Make sure all
points are flow
balanced. 3.
Refer to Flow Path
verification procedure
96117
Modbus Comm. Failure
Interruption during Modbus
communication process.
1. Power cycle unit
2. Contact DOD
Technologies, Inc.
96118
Optic Block Comm. Failure
Communication interruption between
optic block and PC.
1. Refer to Optic
Troubleshooting
Procedure.
96119
Flow Block Comm. Failure
Communication interruption between
Flow board and PC.
1. Refer to Flow
Comm. Fault
Procedure.
96121
Gate Open Fault
Micro switch failed to open during a
tape advance.
1. Refer to Gate Fault
Procedure.
96122
Gate Close Fault
Micro switch failed to close during a
tape advance.
1. Refer to Gate Fault
Procedure.
96123
Setting DAC to preset values
CL96 was unable to set DAC values back
to previously retained values.
1. Power cycle
analyzer
96130
System Fault
System hardware issue.
1. Contact DOD
96131
Block Below Minimum Voltage
Optic block voltage dropped below the
required voltage of 5.1 V
1. Verify 5V supply is
turned up to 6.1 VDC
2. Verify all optic
blocks have at least
5.4 VDC
3. See Optic
Troubleshooting
Procedure
96133
Output Module Failure or Not
Installed
Expected I/O module cannot be located
by the PC.
1. Refer to I/O
Verification
Procedure.
96138
Retentive Memory Error, History
and/or Tape counters may be
corrupt.
Unable to load previous historical
events after power cycle.
1.Power cycle CL96
96140
Idle Timeout (System)
CL96 was left out of analysis for a time
frame that overlapped the time out
setting.
1. Check to see if a
fault caused the CL96
to leave analysis
2. If not put the CL96
back into analysis

Page 14 of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
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96148
Output Module Communication
Error
I/O module communication issue with
the PC.
1. Refer to I/O
Verification
Procedure
96149
Timeout Advancing Parallel
Analyzers
Tape advance issue in parallel analysis
mode.
1. Reset fault and re-
enter analysis
2. If fault reoccurs
contact DOD
Technologies, Inc.
Critical
Fault
CL96 System Fan Failure
Fan on side panel has failed
1. Replace fan on
CL96 side panel
Critical
Fault
Pyrolyzer Control Module Fault
Communication issue between the PC
and pyrolyzer control modules
1. Verify connection
of communication
modules. 2. Unplug
and re-insert cables
on communication
module 3. power
cycle CL96 4. Replace
communication
modules
96114
Low Flow
A point has a flow value below the
required amount of flow
1. Refer to Flow Path
Verification
Procedure
96115
High Flow
A point has a flow value above the
required amount of flow
1. Refer to Flow Path
Verification
Procedure
96120
Idle Timeout (Analyzer)
An analyzer was left out of analysis for a
time frame that overlapped the time
out setting
1. Check to see if a
fault caused the CL96
to leave analysis
2. If not put the CL96
back into analysis
96124
ChemLogic tape low
The tape counter days remaining value
is equal to the warning value setting
1. Replace the
Chemlogic cassette
2. Reset counter
96125
Log write Error-Select Disk in
Setup:
The system cannot locate the data
logging thumb drive to write new data
files
1. Go to
History>>Storage and
press Remove Disk.
2. Remove thumb
drive and reinsert.
3. If fault returns
contact DOD
Technologies, Inc.
96144
Custom Output Module Failure
The PC cannot communicate with the
I/O modules
1. Refer to the I/O
Verification
Procedure.

Page 15 of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
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96146
Output Module Offline
The PC cannot communicate with the
I/O modules
1. Refer to the I/O
Verification
Procedure
96147
Point Disabled Due to High
Background
A point has been disabled due to a high
background
1. Press Verify Optics
button in the Load
Tape screen
96153
Warning: PT Disabled, Check
Optic Block(Ref)
A point was disabled due to reference
fluctuations
1. Replace the optic
block
96154
Pyrolyzer Failure - Point Disabled
A single Pyrolyzer element has failed
1. Replace element
96101
No event file found for selected
date
The CL96 could not locate a log file for
the selected day.
None needed
96102
Starting new log file
New log file started
None needed
96103
Power On
CL96 was powered on
None needed
96106
Faults & Alarms Reset
Faults and alarms were reset.
None needed
96126
Optic Calibrated
Optic calibration was manually
performed.
None needed
96127
Flow Offsets Reset
Flow offset calibration was performed.
None needed
96128
Point configuration
updated/saved
Point Configuration was changed and
saved.
None needed
96129
Machine configuration
updated/saved
System Configuration was changed and
saved.
None needed
96132
Simulation Mode
Simulation Mode started.
None needed
96134
K Factor update
K Factor update
None needed
96135
Passwords updated
Passwords updated
None needed
96136
Multi-Point configuration change
Multi-Point configuration change.
None needed
96137
Previous machine settings
restored.
Previous machine settings restored.
None needed
96139
ChemLogic tape days counter
reset
ChemLogic tape days counter reset.
None needed
96141
PLC Connected
PLC Connected
None needed
96142
Optics Auto Adjusted
Optics Auto Adjusted
None needed
96143
Optic Point Needs Cleaning
Optic Point Needs Cleaning
1. Refer to the Optic
Cleaning Procedure.
96145
Optic Adjustment Suggested
Optic Adjustment Suggested
1. Refer to the Optic
Cleaning Procedure.
96150
Point Alarm Output Disable
Point Alarm Output Disable
None needed
96151
Point Output Disable Timer
Reset
Point Output Disable Timer Reset
None needed
96152
Optic Validation(Ref)
A point has an unstable reference value.
Replace the optic
block
96154
Established PLC Connection
Established PLC Connection
None needed
96155
Restarting PLC Connection
Restarting PLC Connection
None needed

Page 16 of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
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96156
New Logging Span
New Logging Span
None needed
96157
Data Logging Cleanup
Data Logging Cleanup
None needed
96158
New Logging Disk Setup
New Logging Disk Setup
None needed
96159
Gate Open Verification
System had to retry gate open process.
Refer to the Gate
Fault Procedure
96160
Gate Close Verification
System had to retry Gate close process.
Refer to the Gate
Fault Procedure
96161
Factory Log->
Factory Log mode enabled
None needed
96162
PLC:
PLC: message
None needed
96162
Output testing
Output testing was done
None needed
96162
Temperature Validation
Temperature Validation
None needed
Optic Cleaning Procedure:
This procedure should be followed when any of the following messages appear in the CL96 event log:
1. Optic Calibration Required (service fault)
2. Optic point needs cleaning
3. Optic adjustment suggested
The events above may appear in the event log if there is an issue with the optic system. The optic
system is self-adjusting and will make the required adjustments internally when one of the channels
becomes dirty until further action is necessary. If the Optic Calibration Service Fault appears the system
can no longer compensate for the dirty optic channels and the following procedure must be followed:
First enter the System screen by following the steps below:
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 17 of 44
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone [phone] • Fax [phone]
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The screen above should be used to locate the point(s) that need to be cleaned. Press the Calibrate
button to allow the optics to adjust. Locate any point that has a DAC value above 140. Once the points
that need to be cleaned are located gather the following tools:
1. # 2 Phillips screw driver.
2. Cotton swabs
3. A form of Alcohol (methanol, ethanol)
The top of each analyzer will have a point map; use this map to locate the optic block that needs to be
removed. Once the block is located open the related gate by pressing the open gate button and remove
the ChemLogic cassette out of the way. Next, remove the optic block cover by unscrewing out the two
phillips screws (see image below).