DOD CLPX User manual

CLPX
Portable Gas Monitor
User’s Manual
Revision 12.109

CLPXUser’sManual
DOD Technologies, INC
www.dodtec.com
740 McArdle Dr. • Unit C
Crystal Lake, IL 60014
Phone [phone] • Fax [phone]

TABLE OF CONTENTS
IMPORTANT......................................................................................................................................... 2
CHAPTER 1 - OVERVIEW .................................................................................................................. 2
1.1 Introduction................................................................................................................................. 2
1.2 Sampling and Monitoring............................................................................................................ 2
1.3 Flow............................................................................................................................................. 2
1.4 Electrical...................................................................................................................................... 3
1.5 Theory of operation...................................................................................................................... 3
CHAPTER 2 - FEATURES.................................................................................................................... 4
2.1 External Layout ........................................................................................................................... 4
2.1.1 Cassette Access Door................................................................................................................. 4
2.1.2 Keypad & Display...................................................................................................................... 4
2.1.3 ChemLogic tape and Take-up Reel............................................................................................ 5
2.1.4 Gas Inlet/Exhaust ..................................................................................................................... 5
2.1.5 Power........................................................................................................................................ 5
2.2 Micro Secure Digital (SD) card.................................................................................................... 5
CHAPTER 3 – WHAT’S INCLUDED................................................................................................... 6
3.1 Unpacking the CLPX case. .......................................................................................................... 6
CHAPTER 4 – SETUP & CONFIGURATION..................................................................................... 7
4.1 Battery Charging ......................................................................................................................... 7
4.2 Battery Replacement .................................................................................................................... 8
CHAPTER 5 – BASIC OPERATION.................................................................................................... 9
5.1 Using the keypad.......................................................................................................................... 9
CLPX Menu Overview ..................................................................................................................... 11
5.2.a Analysis................................................................................................................................... 11
5.2.b Setup Menu............................................................................................................................. 13
5.2.c SD Card .................................................................................................................................. 13
5.2.d History .................................................................................................................................... 13
5.2.e STEL....................................................................................................................................... 13
5.2.f Verify Tape ............................................................................................................................. 14
5.2.g Service.................................................................................................................................... 14
5.2.h Help ....................................................................................................................................... 14
5.2.i Power Off................................................................................................................................ 14
5.3 SETUP MENU................................................................................................................................ 15
5.3.a Select Gas............................................................................................................................... 15
5.3.b Adjust Flow............................................................................................................................ 15
5.3.c Set Alarm Levels..................................................................................................................... 15
5.3.d Battery Check......................................................................................................................... 16
5.3.e Set Date/Time......................................................................................................................... 16
5.3.f System Info............................................................................................................................. 16
5.3.g Cal Stick Test ......................................................................................................................... 17
5.4 SERVICE MENU ........................................................................................................................... 18
5.4.a Manual Optics Test ................................................................................................................ 18
5.4.c Config Settings....................................................................................................................... 18
5.4.d Pwd Settings........................................................................................................................... 19
5.4.e Battery Settings ...................................................................................................................... 19

5.4.f Simulation .............................................................................................................................. 20
5.4.g Passwords .............................................................................................................................. 20
5.4.h Factory Meuu ........................................................................................................................ 20
5.4.i Software Update (Version 12.3 and higher) ........................................................................... 20
CHAPTER 6 - MAINTENANCE......................................................................................................... 21
6.1 Micro Secure Digital (SD) Card replacement............................................................................. 21
6.2 Routine Maintenance................................................................................................................. 21
6.2.a Inspection of the CLPX........................................................................................................... 21
6.2.b Cleaning the CLPX ................................................................................................................. 21
6.2.c Cleaning the Exterior.............................................................................................................. 22
6.2.d Cleaning the Interior............................................................................................................... 22
6.2.e Cleaning the Gate.................................................................................................................... 22
CHAPTER 7 – SERVICE & SUPPORT.............................................................................................. 23
APPENDIX A – ACCESSORIES......................................................................................................... 24
APPENDIX B ....................................................................................................................................... 25
APPENDIX C – TECHNICAL SPECIFICATIONS ........................................................................... 26
APPENDIX D - SYSTEM EVENT MESSAGES................................................................................. 27
APPENDIX E - GAS SPECIFICATIONS ........................................................................................... 29
APPENDIX F – REMOVABLE MEDIA............................................................................................. 30
F.1 Concentration Log Files (CONCHH.CSV)................................................................................ 31
F.2 Event Log Files (EVENTHH.CSV) ........................................................................................... 31
F.3 STEL Log Files (STELHH.CSV) .............................................................................................. 32
F.4 Formatting Micro SD Disks ...................................................................................................... 32
F.5 Software Update Procedure....................................................................................................... 32
F.5.A CLPX Installer Update......................................................................................................... 33
F.5.B CLPX Softwarer Update....................................................................................................... 34
APPENDIX G – CHEMLOGIC CASSETTES.................................................................................... 35

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IMPORTANT
ELECTRICAL HAZARD
The CLPX may only be serviced by trained service
personnel. Contact the manufacturer for more information
.
Be sure to read this manual in its entirety before installing and operating the CLPX. Contact
the manufacturer with any questions regarding the installation or use of the CLPX.
Chapter1 -Overview
1.1 Introduction
The DOD Technologies CLPX portable gas monitor is an analytical instrument designed to measure
low concentrations of a specific toxic gas or a specific range of related toxic gases or vapors. This
equipment is intended to be used as part of a defined air quality management program.
The CLPX uses DOD Technologies ChemLogic colorimetric technology for fast and accurate gas
detection. The CLPX 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.
1.2 Sampling and Monitoring
The system draws sample flow through the inlet on the front of the unit and through the ChemLogic
tape.
1.3 Flow
An optional kit allows a short exhaust tube to be used with the CLPX unit. Contact DOD for more
information.
IMPORTANT
:
Use only ChemLogic cassettes labeled for use with CLPX.
IMPORTANT : Read Appendix G before handling ChemLogic Cassettes

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1.4 Electrical
The unit is powered with a 6Volt rechargeable Lead Acid Battery. Use only the included charger to charge
the unit.
1.5 Theory of operation
During the analysis cycle the pump draws a measured sample of air through a chemically
impregnated “ChemLogic” paper tape. The ChemLogic tape reacts to the presence of the specific
contaminants by darkening from its original paper color. Light is bounced off the dark stain and
sensitive optics repeatedly measure the degree of change from the original color. The CLPX uses an
advanced optical detection system to measure the light level reflected from the ChemLogic tape. The
instrument calculates the change as the level of gas present in the sample. Extremely small
concentrations can be detected with this method. The instrument stores the gas level readings on the
MicroSD card for transfer to a computer for further analysis in standard comma separated values
(CSV) format.
If the calculated value indicates that the concentration has exceeded either the Low or High
ALARM set points, the instrument will sound an ALARM and flash the concentration level in the
backlit display. The CLPX automatically calculates the Short Term Exposure Limit (STEL) for the
selected gas and stores the readings in the internal data storage memory and to a MicroSD flash
memory card (if installed).
The ChemLogic paper tape is contained within a removable tape cassette. The CLPX monitor
automatically advances the roll to position a fresh segment of tape for gas sampling. Each cassette
is sealed into a protective package, and marked with expiration date and serial number. Cassette life
will vary depending the operational conditions and concentration levels of the gas being monitored.

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Chapter2 -Features
2.1 External Layout
Figure 2.1
2.1.1 Cassette Access Door
The cassette access door is used to load/unload ChemLogic cassettes into the CLPX. To open the door turn
the door latch release knob counter clockwise until it stops which will release the latch from the door. Pull
the door down to insert/remove the cassette. When complete close the door and turn the knob clockwise to
latch the door.
Figure 2.2
2.1.2 Keypad & Display
The CLPX uses a two color LCD display with a 5 button keypad See chapter 5 for a complete description
on the use of the keypad and display.
IMPORTANT: The doo should emain closed and latched except when changing the
ChemLogic cassette.
Doo Latch elease knob

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2.1.3 ChemLogic tape and Take-up Reel
ChemLogic paper tapes are accessed by opening the door as described in section 2.1.1.
2.1.4 Gas Inlet/Exhaust
Sample is pulled through the inlet on the front of the unit, through the paper tape and further scrubbed via a
charcoal filter inside the unit.
2.1.5 Power
Power the unit on by pressing the enter button. See chapter 5 for complete operation.
2.2 Micro Secure Digital (SD) card
The CLPX uses a MicroSD card to store historical information including concentration logging, event
history, STEL and configuration information. SD cards may be purchased through DOD Technologies – see
Appendix A.
Care should be taken when inserting and removing the MicroSD card. Do not insert or remove the MicroSD
card while the machine is in operation. Power down the machine first then insert or remove the MicroSD
card to assure no data is lost or the card is corrupted.
Standard MicroSD cards may be used with either FAT16 or FAT32 format. See Appendix F for information
on the data stored to the MicroSD card.

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Chapter3–What’sincluded
3.1 Unpacking the CLPX case.
The CLPX comes in a convenient durable hard shell storage case with a handle for easy transport. Included
in the case are:
•A 0-500cc flow meter with a short tube for use when adjusting the pump and.verifying proper flow
at any time during sampling.
•A battery charger with a charging indication light
•A shoulder strap with two rings to attach to the CLPX
The case can also hold up to two (2) ChemLogic cassettes. Be sure to read the DOD Technologies
recommended storage guides for the specific types of cassettes being used.
Use care when handling the CLPX portable gas monitor. Although the CLPX monitor is ruggedly
built it is a sensitive instrument. Do not drop the monitor or expose it to excessive moisture or heat
that could cause damage to the mechanism or electronics. Establish a schedule for cleaning and
regularly inspect the unit for damage. If any damage is found or the monitor does not operate as
described in these instructions, remove the unit from service and tag for repair by authorized
personnel.

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Chapter4–Setup&Configuration
Follow this checklist to configure the CLPX for first time operation.
Quick Setup Checklist
1. ___ Set system date and time (section 5.3.e)
2. ___ Gas selection (section 5.3.a)
3. ___ Alarm level settings (section 5.3.b)
4. ___ Install new ChemLogic tape
5. ___ Test the optical system (section 5.4.b)
6. ___ Install removable media (section 6.1)
Setup complete - Ready for monitoring.
4.1 Battery Charging
The Battery charger for the CLPX monitor is an electrical device that has not been evaluated for
intrinsic safety as an ignition source. This device is not to be used in a potentially explosive
atmosphere. Use of the CLPX or Battery charger in a flammable or explosive atmosphere may
result in ignition of the atmosphere resulting in serious injury or death.
WARNING : IF THE CLPX MONITOR DOES NOT OPERATE AS
DESCRIBED IN THESE INSTRUCTIONS, DO NOT USE THE
MONITOR. REMOVE THE UNIT FROM SERVICE AND TAG FOR
REPAIR BY AUTHORIZED PERSONNEL. FAILURE TO CONFIRM
THAT THE MONITOR IS OPERATING PROPERLY MAY RESULT
IN EXPOSING THE USER TO A HAZARDOUS ATMOSPHERE
WHICH COULD RESULT IN SERIOUS INJURY OR DEATH.
WARNING
BATTERY CAN EXPLODE, LEAK, OR CATCH ON FIRE IF
DIRECTLY EXPOSED TO HIGH TEMPERATURE, WATER, OR
FIRE, OF IF OPENED, DISASSEMBLED, OR TAMPERED WITH.
FAILURE TO HANDLE BATTERY PROPERLY MAY RESULT IN
SERIOUS INJURY.
WARNING
DISPOSE OF DAMAGED OR DEFECTIVE BATTERIES IN
ACCORDANCE WITH FEDERAL, STATE, AND LOCAL
ENVIRONMENTAL REGULATIONS. DO NOT THROW AWAY
BATTERIES AS ORDINARY TRASH. FAILURE TO HANDLE
BATTERY PROPERLY MAY RESULT IN SERIOUS INJURY.

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®
To charge the CLPX plug the charger into a power source (120/230 VAC) and then plug the charging
connector into the back of the battery pack. The charger has an indicator light that will glow RED
while the unit is charging or GREEN to indicate the battery is fully charged. The unit will not be
damaged by continued charging after the indicator light turns GREEN.
4.2 Battery Replacement
Battery removal is not normally necessary. To replace the battery or to install a backup
battery follow these steps:
1. Disconnect the battery charger (if connected)
2. Place the CLPX monitor in a clean work area known to be free of potentially explosive
gases or hazards.
3. Verify that the unit is powered OFF (the display screen will be blank).
4. Lay the instrument on one side.
5. The battery pack is mounted to the base of the CLPX monitor with four (4) screws, one
at each corner. Remove the screws with a 9/64" (3.5mm) Allen wrench.
6. Carfeully pull the battery away from the unit and make sure all four screws are
disengaged from the case.
7. Carefully unplug the two pin connector attached to the main board on the CLPX.
.
(4) HEX HEAD SCREWS SECURE BATTERY PACK TO BOTTOM O F
INSTRUMEN T
Figure 4.1
To reinstall the battery :
1. Carefully reattach the two pin connector to the main board making sure the latch snaps
to hold it in place.
2. Align the battery against the case with the charging port on the back of the CLPX.
3. Securely tighten the four screws holding the battery in place.
WARNING
DO NOT REMOVE THE BATTERY FROM THE CLPX MONITOR
IN A POTENTIALLY EXPLOSIVE ATMOSPHERE. REMOVAL OF
THE BATTERY IN A FLAMMABLE OR EXPLOSIVE ATMOSPHERE
MAY RESULT IN IGNITION OF THE ATMOSPHERE RESULTING
IN SERIOUS INJURY OR DEATH

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Chapter5–BasicOperation
5.1 Using the keypad
The CLPX is controlled using the 5-key keypad located under the display. All of the display screens are
accessed through a simple menu system as shown in figure 5.1
Figure 5.1
A) On most screens the available keys will be shown on the display. Much of the time the top row indicates
which keys to use.
B) Menus – Use the UP/DOWN keys as shown in Figure 5.1 to navigate through the menu items then use
the ENTER key to select the highlighted item. From any sub-menu (setup,service, etc) use the LEFT
key to return to the previous menu.
C) Password – For access to restricted screens the system will prompt for the appropriate password.
Figure 5.2
Use the LEFT/RIGHT keys to select each digit and the UP/DOWN to change the value of the selected
digit. Press the ENTER key when complete to check the password. You can always change the value to
0 and press the ENTER key to return to the previous menu item.
D) Normal data entry – Most data entry can be accomplished by simple use of the LEFT/RIGHT keys to
select/change values as shown in figure 5.3
Use Ente
Key
The top ow
shows
available key
options.
Mo e items available by
using down key to sc oll

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Figure 5.3
Some data items require detailed editing as shown in figure 5.3 When the ‘EDIT’ item appears on the top
row for a highlighted value the operator can either use the LEFT/RIGHT to change the value or use the
ENTER key to enter the value directly – see Detailed data entry below.
E) Detailed data entry – When detailed data entry is selected a screen similar to Figure 5.4 will display
allowing the operator to enter each digit as desired similar to password entry
Figure 5.4
Use the LEFT/RIGHT keys to select each digit and the UP/DOWN to change the value of the selected
digit. The minimum and maximum allowed values will be displayed. Press the ENTER key when
complete to submit the new value and return to the previous data entry screen.
Change the
highlighted value
by using the
left/ ight keys.
Select which
item to edit
using
up/down
The bottom ow shows available save/exit/escape options fo each sc een.
This item indicates
detailed editing
available fo the
highlighted item.

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CLPX Menu Overview
5.2 Main Menu
Once the CLPX is configured the main menu contains all the screens necessary for normal operation. The
main menu is not password protected. Each selection on the main menu is detailed below.
Note 1: The setup menu is not password protected by default.
Note 2: The service menu is password protected by default.
Passwords can be changed/cleared in the Password screen on the Service Menu (5.6.c)
5.2.a Analysis
Figure 5.4
Analysis
Setup
SD Card
History
STEL
Verify Tape
Service
Help
Power Off
Manual Optics Test
Auto Optics Test
Config Settings
Pwd Settings
Battery Settings
Simulation
Passwords
Factory Menu
Software Update
Service Menu
Main Menu (5.2)
Select Gas
Adjust Flow
Set Alarm Levels
Battery Check
Set Date/Time
System Info
Cal Stick Test
Setup Menu

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Selecting this menu item will start gas analysis and bring up the screen in figure 5.4. During this phase the
tape will advance and the system will verify the optical system and adjust the light intensity if necessary.
Once the optical system is verified the analysis screen shown in figure 5.4 will be displayed and the pump
will start.
Figure 5.4
•NOTE 1 – An asterisk in the lower right corner indicates the machine has past the time necessary to
detect the LDL for the selected gas since the last tape advance. The asterisk will disappear and the
timer reset at each tape advance. Press the down arrow to reset the timer when looking for LDL at
another location.
The words ‘Alarm Level 1’ and ‘Alarm Level 2’ will blink when the concentration meets or exceeds the
preset alarm levels. Alarm Level 1 blinks at a 2 second rate while Alarm Level 1 blinks at a 1 second rate.
In addition the letters ‘SD’ will appear in the upper left corner under the up arrow when there is an error
writing the MicroSD’ card or there is no MicroSD card inserted.
The status line displayed between the cassette part number and the gas/range display will show various
information about the current analysis cycle :
•Beyond Full Scale (Actual concentration exceeds full scale)
•Shutdown in X seconds (battery voltage below shutdown level)
•Low Battery (battery voltage below alarm level)
•Adv Pending (preparing/advancing cassette)
P ess up button to
exit analysis.
Cassette that should
be used fo selected
gas.
Selected gas being
monito ed. and ange
P eset ala m levels
Concent ation
and unit of
measu e
S
tain development
Status line
*SEE NOTE 1
Note : During analysis detailed information is viewable by using the
LEFT key This screen may be useful for service and repair To return to
the main analysis screen presss the LEFT key again

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5.2.b Setup Menu
The Setup Menu contains the screens necessary to configure the CLPX for operation. The setup menu is not
password protected by default but may be password protected (see service menu).
5.2.c SD Card
The SD Card screen displays the amount of empty space remaining on the MicroSD card. Check this value
before each use to assure adequate space remains to log STEL, Concentration, and event history to the card.
5.2.d History
The recent event history is kept in the CLPX regardless of whether an SD card is inserted or not. A
minimum of 16 events are kept at all times although many more events are normally stored depending on
memory usage. See appendix D for description of CLPX events.
Figure 5.5
The most recent event is always shown first. Use the UP/DOWN keys to scroll through recent events and
the LEFT key to exit back to the main menu. You can also use the RIGHT key for more information on
selected events. When the right key is pressed the screen shown in figure 5.6 will display.
Figure 5.6
Depending on the event this may give more detailed information or diagnostic information on the event. The
‘DIAG’ codes displayed at the bottom are useful when contacting DOD Support.
5.2.e STEL
The resent STEL event history is kept in the CLPX regardless of whether an SD card is inserted or not. A
minimum of 16 STEL values are stored depending on the memory usage of the CLPX. The most recent
STEL reading will be displayed as shown in figure 5.7

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Figure 5.7
At the conclusion of each analysis cycle a new STEL value is added to the log. The time of the highest value
is displayed on the screen along with the STEL concentration value. Detailed information is also written to
the MicroSD card at the same time (if a properly formatted card is inserted).
5.2.f Verify Tape
When this item is selected a screen similar to Figure 5.8 will display showing the current selected gas and
which ChemLogic cassette should be inserted. Use this anytime to check that the proper tape is installed.
Figure 5.8
5.2.g Service
The Service Menu contains the screens necessary for testing and configuration of the CLPX. It is not
normally accessed after the machine is initially configured. See section 5.4 for details. Note that the Service
menu is always password protected.
5.2.h Help
The Help menu contains basic information on the operation of the CLPX. Browse through the help screens
using the UP/DOWN arrows and use the left arrow to exit back to the menu.
5.2.i Power Off
To power off the CLPX select this item and answer YES to the “Are you sure?” screen that appears. Note
that this screen can be quickly accessed by using the UP arrow from the top of the menu so the operator can
exit analysis, press UP to get to this item then ENTER and answer YES to power off quicly.

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5.3SetupMenu
The setup menu is not password protected by default. In the Configuration settings on the Service Menu the
password requirement can be enabled if needed.
5.3.a Select Gas
This selection will display the available gas selections based on the gas family purchased and installed at the
factory. Use the ENTER key to select the gas to monitor for which will then set the default Alarm Levels and
give the operator the opportunity to change them by going directly to the Set Alarm Level screen (see 5.3.c)
Figure 5.8
5.3.b Adjust Flow
This selection will display the screen shown in figure 5.9. Connect the included flow meter and adjust the
pump to get the flow to the value shown. (ex 200 cc). As shown in the screen you can normally adjust the
pump using the left right keys or if you would like to enter a specific value press the ENTER key and use the
procedure outlined in 5.1 E
Figure 5.9
5.3.c Set Alarm Levels
This selection will display the screen shown in figure 5.10 to adjust the Alarm Level if necessary. When a
gas is selected the alarm levels are set to the default values which are normally 1 and 2 TLV. They can be
adjusted if necessary at anytime in this screen. Be sure to selecte ‘SAVE’ when done if the values are
changed.

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Figure 5.10
5.3.d Battery Check
The battery check menu will display the screen shown in figure 5.11 which displays the current battery
voltage along with the warning and shutdown levels. These levels can be adjusted if necessary (not
recommended) on the Service Menu.
Figure 5.11
5.3.e Set Date/Time
Allows the operator to change the Date/Time. Note the hour displayed is in 24 hour format. Use the
LEFT/RIGHT keys to quick adjust each field and the UP/DOWN keys to select each field.
Figure 5.12
5.3.f System Info
Displays the current software version and serial # and selected gas for information purposes only. Software
versions 12.3 and higher will also display the Installer/Updater version #.

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5.3.g Cal Stick Test
The Cal Stick included with in the case is not necessary for calibrating the system as the optics will self-
calibrate however the Cal Stick Test screen allows for verifying that the optics can adjust appropriately and
detect color change.
NOTE : It is recommended to perform an Optics Auto Test on the Service menu after running the CAL Stick
Test.
Figure 5.14 Figure 5.15 Figure 5.16
To run the Cal Stick test follow the directions on the screen. Insert Cal Stick side 1, then Cal Stick Side 2
and view the results . The screen will display an error if the values are out of range or otherwise invalid.