DOD ChemLogic 1 User Manual

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ChemLogic 1

Single Point Continuous Gas Monitor

User’s Manual

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DECLARATION OF CONFORMITY

DOD TECHNOLOGIES INC. 740 McArdle DR. Unit C Crystal Lake, Illinois 60014

We declare under our sole responsibility that the product described as:

ChemLogic 1 (CL1)

Complies with the requirements of the Directives:

- Machinery Directive 98/37/EC (amended);

- Low Voltage Directive 2006/95/EC

- Electromagnetic Compatibility Directive 2004/108/EC

Standards considered:

EN 12100-1, EN 12100-2, EN 60204-1, EN 61000-6-2, EN 61000-6-4

Date: 12 / 3 / 2007 At: 10:00 am

Daniel ODonnell

Daniel ODonnellDaniel ODonnell

Daniel O'Donnell

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ChemLogic 1 User’s Manual

Default Passwords

Setup Menu 0

Service Menu 1234

 DOD Technologies, INC

www.dodtec.com

740 McArdle Dr. • Unit C

Crystal Lake, IL 60014

Phone 815.788.5200 • Fax 815.788.5300

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TABLE OF CONTENTS

IMPORTANT ............................................................................................................................................... 1

CHAPTER 1 - OVERVIEW........................................................................................................................ 2

1.1 Introduction....................................................................................................................................... 2

1.2 Sampling and Monitoring ................................................................................................................. 2

1.3 Flow Connections.............................................................................................................................. 2

1.4 Electrical Connections ...................................................................................................................... 2

1.5 Theory of operation ........................................................................................................................... 2

CHAPTER 2 - FEATURES ......................................................................................................................... 3

2.1 External Layout................................................................................................................................. 3

2.1.1 Maintenance door .......................................................................................................................... 3

2.1.2 Keypad & Display ........................................................................................................................... 3

2.1.3 ChemLogic tape and Take-up Reel................................................................................................ 3

2.1.4 Gas Inlet/Exhaust........................................................................................................................... 3

2.1.5 A/C Power & Switch....................................................................................................................... 4

2.1.6 14 Pin I/O Connector ..................................................................................................................... 4

2.2 Maintenance area.............................................................................................................................. 4

2.3 Internal Layout – Service area ......................................................................................................... 4

2.5 Micro Secure Digital (SD) card ........................................................................................................ 5

CHAPTER 3 - INSTALLATION................................................................................................................ 6

3.1 Selecting a location ........................................................................................................................... 6

3.2 Mounting ........................................................................................................................................... 6

3.3 Sample Tubing .................................................................................................................................. 8

3.3.2 End of line particulate filters ......................................................................................................... 8

3.4 Exhaust tubing .................................................................................................................................. 8

3.5 A/C Power.......................................................................................................................................... 8

3.6 Output Wiring.................................................................................................................................... 8

CHAPTER 4 – SETUP & CONFIGURATION......................................................................................... 9

CHAPTER 4 – SETUP & CONFIGURATION....................................................................................... 10

CHAPTER 5 – BASIC OPERATION ...................................................................................................... 11

5.1 Using the keypad ............................................................................................................................. 11

5.2 Alarm & Fault screens .................................................................................................................... 12

CL1 Menu Overview.............................................................................................................................. 13

5.3 Power on Initialization .................................................................................................................... 13

5.4 Main Menu ...................................................................................................................................... 13

5.4.a Start Analysis (Figure 5.7) ........................................................................................................... 14

5.4.b System Faults (Figure 5.8)........................................................................................................... 15

5.4.c Gas Alarms (Figure 5.9)............................................................................................................... 15

5.4.d Gate & Tape (Figure 5.10) ........................................................................................................... 15

5.4.e Alarm Levels (Figure 5.11) .......................................................................................................... 15

5.4.f Event/Alarm History (Figure 5.12) ............................................................................................. 16

5.4.g Test Alarms (Figure 5.13) ............................................................................................................ 16

5.5 Setup Menu (Figure 5.14)............................................................................................................... 17

5.5.a Main Menu ................................................................................................................................... 17

5.5.b Tape Saver (Figure 5.15) (Default configuration : Disabled) .................................................... 17

5.5.c Latching Relays (Figure 5.17) (Default configuration : ON) ................................................... 18

5.5.d Enable Pumps (Figure 5.18) (Default configuration : Enabled) ............................................... 19

5.5.e Enable Points (Default configuration : Only available on CL2) ................................................ 19

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5.5.f Energized Alarm Relays (Figure 5.19) (Default configuration : Off) ....................................... 19

5.5.g Idle Timeout (Figure 5.20) (Default configuration : 45 Minutes)........................................... 19

5.5.h Date/Time (Figure 5.21) .............................................................................................................. 20

5.5.i Test 4-20ma (Figure 5.22) ............................................................................................................ 20

5.5.i Select Gas (Figure 5.24)............................................................................................................... 20

5.5.j Conc. Logging (Figure 5.25) ........................................................................................................ 20

5.6.a Main Menu ................................................................................................................................... 22

5.6.b Optic Calib (Figure 5.26) ............................................................................................................. 22

5.6.c Passwords(Figure 5.27)................................................................................................................ 22

5.6.d Optic Config ................................................................................................................................. 22

5.6.e Status............................................................................................................................................. 23

5.6.f Clear History (Figure 5.28) .......................................................................................................... 23

5.6.g Configuration ............................................................................................................................... 23

CHAPTER 6 - MAINTENANCE.............................................................................................................. 24

6.1 Maintenance Door Access............................................................................................................... 24

6.2 Service Door Access ........................................................................................................................ 24

6.3 ChemLogic Paper tape .................................................................................................................... 25

ChemLogic Paper Tape Path ................................................................................................................ 25

6.4 End of line particulate filters .......................................................................................................... 26

6.4 End of line particulate filters .......................................................................................................... 27

6.5 Flow adjustment .............................................................................................................................. 27

6.6 Micro Secure Digital (SD) Card replacement ................................................................................ 27

6.4 End of line particulate filters .......................................................................................................... 28

6.7 Fuse Replacement ........................................................................................................................... 28

6.8 Apply grease periodically ................................................................................................................ 28

APPENDIX A – ACCESSORIES ............................................................................................................. 30

APPENDIX B – I/O CONNECTION DETAIL ....................................................................................... 31

APPENDIX C – TECHNICAL SPECIFICATIONS............................................................................... 32

APPENDIX D - SYSTEM EVENT MESSAGES..................................................................................... 33

APPENDIX E - GAS SPECIFICATIONS ............................................................................................... 36

APPENDIX F – REMOVABLE MEDIA ................................................................................................. 37

F.1 Concentration Log Files (YYMMDD*.CSV) ................................................................................. 37

F.2 Event Log Files (YYMMDD*.CSV) ............................................................................................... 37

F.3 Formatting Micro SD Disks ........................................................................................................... 38

APPENDIX G – CHEMLOGIC CASSETTES........................................................................................ 40

APPENDIX H – OPTIC BLOCK CLEANING PROCEDURE ............................................................ 41

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IMPORTANT

: Read Appendix G before handling ChemLogic Cassett

es.

IMPORTANT

Only trained operators must be allowed to work on the Cl1.

ELECTRICAL HAZARD

The CL1 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 CL1. Contact the manufacturer with any questions regarding the installation or use of the CL1.

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Chapter 1 - Overview

1.1 Introduction

The DOD Technologies ChemLogic 1 (CL1) continuously monitors a single location (called a point) for toxic and corrosive gas. It responds to gas that exceed a programmed alarm level by:

• Triggering visual alarms on the display that warn of high or low concentrations

• Triggering relays or activating analog outputs to external devices

• Displaying the gas type and gas concentration

• Recording the alarm information and storing it to removable storage.

The CL1 triggers relays for two levels of gas concentrations. These programmable limits are factory-set at 1 TLV and 2 TLV for their respective gases.

The point may be up to 150feet (45 m) from the CL1 location depending on the type of gas being monitored. This allows operators to monitor the gas concentration in an area removed from the location where gas may actually be leaking.

The CL1 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 CL1 uses DOD Technologies ChemLogic paper tape technology for fast and accurate gas detection.

1.2 Sampling and Monitoring The system draws sample flow through the inlet on the bottom of the unit and across the ChemLogic tape. The gas is then exhausted through a port on the side of the CL1.

1.3 Flow Connections

Flow connections consist of “quick-connect” ports on the bottom and side of the CL1. There is one inlet and one exhaust outlet.

1.4 Electrical Connections

The unit is powered with a standard AC Power plug. A single 14 pin connector on the side of the CL1 provides all electrical connections for the outputs and remote reset.

1.5 Theory of operation

The sample flow is diverted across the ChemLogic Tape. The CHEMLOGIC 1 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 1. The CHEMLOGIC 1 will then report an appropriate gas concentration reading and/or a gas alarm.

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Chapter 2 - Features

2.1 External Layout

Maintenance Door

Exhaust Outlet

14 pin I/O Connector

A/C Power & Switch

Gas tubing inlet (underside)

Keypad & Display

Take-up reel

Door latches (side of unit)

ChemLogic Tape

Figure 2.1

2.1.1 Maintenance door

The maintenance door allows easy access to the ChemLogic tape and the display/keypad. The latches on the side of the unit are used to open & close/secure the door.

IMPORTANT: The maintenance door should remain closed and latched except when changing the ChemLogic tape.

2.1.2 Keypad & Display

The CL1 uses a two color LCD display with a 20 button keypad including 4 programmable “soft keys”. See chapter 5 for a complete description on the use of the keypad and display.

2.1.3 ChemLogic tape and Take-up Reel

ChemLogic paper tapes are accessed by opening the maintenance door. Refer to chapter 6 regarding tape installation/replacement.

2.1.4 Gas Inlet/Exhaust

The gas being monitored flows through the inlet on the bottom of the unit, across the paper tape and out the exhaust port on the side of the CL1. Sample tubing and exhaust use a quick connection system for simple installation. See section 3.3 for information on connecting the sample and exhaust tubing.

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. IMPORTANT:

DANGER:

End of line filters are required. See section 6.4

2.1.5 A/C Power & Switch

A/C power is connected on the left side panel with a standard power cord. The on/off power switch is located adjacent to the power cord connection.

2.1.6 14 Pin I/O Connector

The connector on the side of the unit connects to alarm relays, fault relays, 4-20ma output, and the remote reset input.

2.2 Maintenance area

The maintenance area allows easy access for changing ChemLogic tape in the CL1. Figure

2.2 shows the internal layout with the access panel open. See section 6.3 for tape installation.

Figure 2.2

2.3 Internal Layout – Service area

Internal access to the CL1 for service uses the latches located on the right side of the front panel. Figure 2.3 shows the internal layout of the CL1 with the service door open.

Turn off the unit and disconnect A/C power to the unit before

opening the Service Door.

The door should be opened by trained service personnel (See section 6.2)

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Inside w/Serv

ice Door

Back of Service Door

Output Connection Block

SD Card access door

Easy access

Power Supply

long life pumps

Figure 2.3

2.5 Micro Secure Digital (SD) card

The CL1 uses a SD card to store historical information including concentration logging, event history, configuration information, and TWA data. SD cards may be purchased through DOD Technologies – see Appendix A.

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Chapter 3 - Installation

3.1 Selecting a location

The CL1 should be placed in a location as central as possible to the locations being monitored while considering the following restrictions:

♦ The maximum sample line length is 150 ft. for all gases other than Diisocyanates. ♦ Diisocyanates have a 6” maximum sample line ♦ Using the shortest possible sample line length will reduce transport times and increase

the response time of the CL1.

♦ A/C power is required to the unit. ♦ Locate near proper ventilation keeping in mind the maximum length of the exhaust

tubing is 25ft.

♦ The CL1 requires stable temperature and humidity levels within range to operate

properly.

3.2 Mounting

Refer to figure 3.1 for dimensional requirements for wall mount. Be sure the CL1 is properly secured to the wall.

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Figure 3.1

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IMPORTANT:

Gas inlet

3.3 Sample Tubing

Sample tubing connects to the CL1 through the inlet on the bottom of the unit. (see Figure

3.2). Sample tubing must be FEP 1/4 OD x 1/8 ID (150 ft max length – 6” for diisocyanates) which may be purchased from DOD Technologies, INC (See Appendix A).

on bottom of CL1

Figure 3.2

Fully depress the sample tube into fitting past the O-Ring when attaching. To detach the tube, push on the collet and pull the tubing out.

Sample tubing used with the CL1 must be 1/4”OD x 1/8” ID FEP. Use of any other tubing may damage the CL1 and/or cause inaccurate gas concentration readings.

3.3.2 End of line particulate filters

An end of line particulate filter must be used on all gasses except Diisocyanates to prevent loss of concentration. Filters require regular maintenance – see chapter 6.

The CL1 requires filtration to prevent dust accumulation in tubing

and internal damage to the unit. Dust that collects in the tubing or the internal system may cause sample loss and inaccurate gas concentration readings.

End of line particulate filters may be purchased from DOD technologies (see appendix A)

3.4 Exhaust tubing

The exhaust line must be ¼”OD x 3/16” ID tubing with a maximum length of 25ft. Polyethylene is recommended although polypropylene or Teflon may also be used. Exhaust tubing may be purchased from DOD technologies (see appendix A)

3.5 A/C Power

A 6ft power cord is included – DO NOT use extension cords with the CL1. Longer cords are available from most electrical supply stores.

3.6 Output Wiring

The output relays for Alarm Level 1 and System Fault are rated at 6 amp maximum.

The 4-20ma output is adjustable within the CL1 to increase precision. When not in analysis the CL1 will output the 2ma calibrated value. There is a maximum of 500 ohm load impedance on the 4-20ma circuit.

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DANGER:

See Appendix B for a listing of output module connections.

Before doing any wiring modifications be sure that power to

the CL18 is disconnected.

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Chapter 4 – Setup & Configuration

Follow this checklist to configure the CL1 for first time operation.

1. ___ Set passwords (section 5.6.c)

2. ___ Set system date and time (section 5.5.g)

3. ___ Gas selection (section 5.5.i)

Appendix E contains the specifications for each gas.

4. ___ Alarm level settings (section 5.4.e)

5. ___ Latching relays (section 5.5.c)

6. ___ Energized Relays (section 5.5.e)

7. ___ Idle Timeout (section 5.5.f)

8. ___ Testing Contacts (section 5.4.g)

9. ___ Adjustment of 4-20 ma (section 5.5.h)

10. ___ Install new ChemLogic tape (section 6.3)

11. ___ Install removable media (section 6.6)

12. ___ Format removable media (Appendix F.3)

13. ___ Tape Saver Mode (TSM section 5.5.b)

14. ___ Grease the Gate Cam (section 6.7)

Setup complete - Ready for monitoring.

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Note 2

Note

Chapter 5 – Basic Operation

5.1 Using the keypad

The CL1 is controlled using the keypad located around the display. All of the display screens are accessed through a simple menu system.

Figure 5.1

1) The arrow keys located under the screen are used for two purposes.

a. To navigate through the menus using the <ENTER> key to select the highlighted

item on the menu. In most cases the <ESC> key will exit the current screen and return to the top of the previous menu.

b. To select among multiple data fields on some of the screens for editing.

2) The arrow keys on the sides of the display referred to as “soft keys” are used only when associated with a button on a screen. The use of these keys varies from screen to screen – see the detailed descriptions later in this chapter.

3) When numeric entry is required on any screen the following procedure is used.

1. Use the arrow keys below the screen to select which field to edit. The currently

selected box will have a dashed line around it.

2. Press the <ENTER> key first

3. Use the numeric/function keys to enter the value

4. Also note the up arrow may be used for +/- and the down arrow may be used for the

decimal point when necessary.

5. Press the <ENTER> key again to complete the entry

NOTE: The <F1> key is used to exit analysis and return to the main menu.

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5.2 Alarm & Fault screens

Three types of messages used in the CL1:

1. Alarm messages (level 1 and level 2)

2. System faults (critical faults that terminate and/or prevent analysis)

3. Event messages (warnings, non-critical faults, and various events)

See Appendix D for a description of each message. The history log keeps the most recent 128 messages of any type in memory at all times. All three types of messages are also logged to the Micro SD card if present.

Various screens are used in the CL1 to show some or all of the messages (figure 5.2). Each of these screens work in a similar manner.

Figure 5.2

The arrow next to the upper left soft key indicates to press that key to view the full log. When the soft key is pressed a screen similar to figure 5.3 will be displayed. Pressing the <ESC> key will return to the previous menu or screen.

Figure 5.3

From the screen shown in figure 5.3 the arrow keys below the screen allow scrolling of the messages in the log. On some of the fault/event screens the <F4> key will acknowledge all the current fault/events. NOTE: The history log does not allow messages to be cleared. The details for each screen in section 5.4 – 5.6 will describe which keys may be used.

Pressing the <ESC> key once will return to the screen in figure 5.2. Pressing the <ESC> key again from that screen will return to the previous menu or screen.

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Main Me

nu (5.4)

Power Up (5.3)

CL1 Menu Overview

Setup Menu (5.5)

Setup Mode

Auto Analysis Timer

Start Analysis

System Faults

Gas Alarms

Gate & Tape

Alarm Levels

Event/Alarm History

Test Alarms

Setup Menu

Service Menu

See Note 1

Main Menu (return to)

Tape Saver

Latching Relays

Enable Pumps

Enable Points

Alarm Relays

Idle Timeout

Date/Time

Test 4-20ma

Select Gas

Conc. Logging

Service Menu (5.6)

See Note 2

Main Menu

Optic Calib.

Passwords

Status

Optic Config

Clear History

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)

5.3 Power on Initialization

When the CL1 is powered on it will begin with an initialization screen (figure 5.4) which is followed by the restart screen (figure 5.5).

Figure 5.4 Figure 5.5

If the operator touches the <MENU> soft key before the timer reaches 0 the Main Menu(section 5.4.) appears otherwise after a timeout the system will automatically start analysis (section 5.4.a)

5.4 Main Menu

Once the CL1 is configured the main menu contains all the screens necessary for normal operation. The main menu is not password protected.

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Current gas being monitored

Blinking

Tape Saver Mode

Press to display current

Current gas concentration and units

Press to display

current

s concentration bar

Text blinks during alarm

Current alarm levels

P1 or P2 flashing display

Indicates new

When Tape Saver Mode

Figure 5.6

Each selection on the main menu is detailed below

5.4.a Start Analysis (Figure 5.7)

Selecting this menu item will bring up the analysis screen below and start gas analysis. Pressing <F1> during analysis will end analysis and return to the main menu.

indicator and timer. is NOT active, displays # of days remaining on Chemlogic Tape.

See Sec 5.4.b

graph displays % of full scale.

“Full Scale” text displayed when appropriate

and scale used

when pump disabled.

gas alarms

warnings & events

warning/event message(s)

Figure 5.7

The screen continuously displays the current gas concentration as long as the system remains in analysis mode.

WARNING – Tape Saver Mode may affect the display of actual gas concentration. See section 5.5.b for a complete explanation of Tape Saver Mode (TSM).

When the concentration exceeds one or both of the alarm levels the text “Alarm 1” and “Alarm 2” will blink appropriately. Anytime Alarm 1 is active the concentration display will also blink. When the concentration passes the alarm levels the corresponding alarm output relay is triggered. The trigger will remain set depending on the setting of Latching Relays – see section 5.4.c .

The bar graph on the right side of the display reflects the % of full scale for the current concentration reading. At the lower left of the screen the display will show ‘P1’ or ‘P2’ if a pump is disabled either manually or automatically. See section 5.4.d

During analysis the two keys on the right side of the display are active. When pressed the upper right key next to the alarm levels will display a screen showing the current alarm messages. Analysis remains active while this screen is displayed. If alarms are active they may be cleared by pressing <F4> (see alarm screen operation in section 5.3.f). NOTE : If an alarm is cleared but gas is still present above the present alarm level the alarm will immediately trigger once again. Pressing <ESC> will return to the analysis screen.

An asterisk next to the lower right soft key indicates that there are new warning/fault messages. Pressing the key on the lower right next to the asterisk will display the messages while remaining in analysis mode. Any active warning/fault messages may be cleared by pressing <F4> (see alarm screen operation in section 5.3.f). Pressing <ESC> will return to the analysis screen.

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Status Area

5.4.b System Faults (Figure 5.8)

See section 5.2 for the use of the fault/alarm screens. The <F4> key is available to clear messages from the detail screen. The <ESC> key will return to the main menu.

Figure 5.8

5.4.c Gas Alarms (Figure 5.9)

See section 5.2 for the use of the fault/alarm screens. The <F4> key is available to clear messages from the detail screen. The <ESC> key will return to the main menu.

Figure 5.9

5.4.d Gate & Tape (Figure 5.10)

Touch the lower left <GATE> soft key to open or close the gate. When a new Chemlogic tape is loaded press the <RESET> soft key to reset the counter for a new tape. The tape windows remaining displays the number of tape advances expected before the tape is empty. This number is used in the calculation of the warning message “Chemlogic Tape Low”. Press the <DONE> soft key to return to the main menu.

Figure 5.10

5.4.e Alarm Levels (Figure 5.11)

Use the arrow keys below the screen to select between Alarm 1 and Alarm 2. Notice the dotted line around the currently selected field. To enter a new alarm level follow the procedure outlined in section 5.1There are several errors that can occur and will be displayed in the “Status Area” of the screen. . Press the <DONE> soft key to return to the main menu.

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Figure 5.11

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5.4.f Event/Alarm History (Figure 5.12)

See section 5.2 for the use of the fault/alarm screens. The messages shown in the history log cannot be cleared or acknowledged. The most recent 128 messages are contained in the history log. The <ESC> key will return to the main menu.

Figure 5.12

5.4.g Test Alarms (Figure 5.13)

Use the <ALARM 1>, <ALARM 2>, and <FAULT> soft keys to turn the output relays on and off. When the <Done> soft key is pressed all of the faults are automatically reset.

Figure 5.13

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Current Mode

Current state of Tape

# of seconds to wait before

“Trigger” Concentration

Use this soft key to select

Use this soft key to toggle

5.5 Setup Menu (Figure 5.14)

The Setup Menu contains the screens necessary to configure the CL1 for operation. The setup menu is not password protected by default but may be password protected (see service menu).

Figure 5.14

Each selection on the setup menu is detailed below

5.5.a Main Menu

Selecting this menu item will return to the main menu (Section 5.4)

5.5.b Tape Saver (Figure 5.15) (Default configuration : Disabled)

DANGER: Make sure the Tape Saver Modes are completely understood before

enabling. Tape Saver modes allow the operator to bypass continuous gas monitoring.

Tape Saver Mode is used to reduce tape advancement during a gas release. Three tape saver modes are available on the CL1 : Fixed Cycle mode(Default), Single Reading, and Continuous. Use the upper left soft key to select among the three modes.

among 3 Modes

tape advance

TSM on and off.

Saver Mode

Figure 5.15

In Fixed Cycle mode the Minutes entered on the screen is the MINIMUM time each cycle will take regardless of whether gas is detected or not. The maximum time of the cycle is the normal cycle time of the CL1 tape being used(normally approx 54 minutes). Enter the # of minutes (1-54) which will be the minimum time before tape advance. If gas is detected and the tape becomes saturated in less than the time specified, the system will wait until the cycle time is complete before advancing. When this occurs the timer on the Analysis screen will begin counting down the # of seconds remaining until tape advance. In Fixed Cycle Mode

the conc. Level is not used and will always show a non-zero value.

In Single reading mode the time specified (minutes) is the exact analysis cycle time. At the start of each cycle the system will take 1 reading and report the concentration(including zero). The timer will then continue to countdown to zero before advancing to the next cycle. In

Single Reading Mode the conc. Level is not used and will always show 0.

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‘TSM’ displayed whenever Tape Saver

TSM seconds counter counts down to 0

In Continuous mode both the time (minutes) and the conc. Level are used. If the concentration should reach the level specified the timer will start and count down from the time specified to zero before advancing the tape.

Figure 5.15

WARNING – When tape saver mode is active the actual gas concentration may not be displayed. Anytime the counter (in seconds – see figure 5.16) is counting down to zero NO ANALYSIS IS BEING PERFORMED and the concentration displayed may not be accurate.

While tape saver mode is enabled the letters ‘TSM’ will always appear on the analysis screen.

before tape advance. During this time no analysis is done.

Mode is enabled. Blinking ‘TSM’ indicates TSM counter running.

Figure 5.16

Example using figures 5.15 and 5.16: When the values displayed in figure 5.15 are entered and TSM is enabled (ON), a gas concentration reading of 100.3 would start the TSM counter and freeze the concentration reading at 100.3 ppb.(see figure 5.16) Regardless of the amount of gas present during this time the counter will start at 300 seconds and countdown to 0 before advancing the tape and calculating a new gas concentration.

After the tape advance the CL1 will again monitor for gas and display the calculated value. If the new calculated value is below the TSM concentration the concentration displayed will begin to update appropriately. Once the gas concentration reaches 100.0 the timer will start again and the value will remain at the last calculated concentration.

5.5.c Latching Relays (Figure 5.17) (Default configuration : ON)

Press the upper left soft key to toggle the latching relays on and off. The display adjacent to the soft key always displays the current state of the relays. (ex : in figure 5.17 the relays are currently non-latching).

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Figure 5.17

Latching relays will cause a gas alarm relay to remain active even if the gas concentration drops below the alarm level until it is acknowledged. If the relays are set to non-latching the output the relay outputs will toggle on and off as the gas concentration goes above and below the corresponding alarm level.

5.5.d Enable Pumps (Figure 5.18) (Default configuration : Enabled)

Press the upper soft keys to toggle between enabled/disabled on the corresponding pump. The display adjacent to the soft key always displays the current state of the pump. (ex : in figure

5.18 both pumps are currently enabled). When a pump is disabled a flashing ‘P1’ or ‘P2’ corresponding to the disabled pump will appear in the lower left corner of the analysis screen. (See section 5.4.b) Disabling both pumps will trigger a critical system fault and prevent analysis mode.

Figure 5.18

5.5.e Enable Points (Default configuration : Only available on CL2)

Similar to the Enable Pumps screen, this screen will allow either point on a CL2 to be enabled/disabled.

5.5.f Energized Alarm Relays (Figure 5.19) (Default configuration : Off)

Use the upper left soft key to select Energize/De-Energized alarm relays. The soft key always shows the CURRENT state of the relays The initial default value is Energized.

Figure 5.19

5.5.g Idle Timeout (Figure 5.20) (Default configuration : 45 Minutes)

Enter the number of minutes before an ‘Idle Timeout Fault’ occurs. When the system is out of analysis for the specified amount of time the fault will occur. Specifying zero(0) minutes will disable the fault from occurring. The maximum amount of time allowed is 45 minutes.

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Figure 5.20

5.5.h Date/Time (Figure 5.21)

Use the arrow keys below the screen to select among the date & time fields and enter the values using the procedure outlined in section 5.1.3. The <SET> soft key must be pressed

to apply the changes that are entered.

Figure 5.21

5.5.i Test 4-20ma (Figure 5.22)

Use the soft keys to select 2 ma, 4 ma, or 20 ma. which will bring up the screen in figure 5.23 AND set the 4-20ma output to the corresponding level. Using the “-“ or “+” soft keys the output value can be adjusted as needed for the selected level. The adjusted value is automatically saved each time the “-“ or “+” soft key is used. The new values are permanently stored in the CL1 and used in the 4-20ma scaling for gas concentrations.

Figure 5.22 Figure 5.23

5.5.i Select Gas (Figure 5.24)

Selecting this menu item will display the gas selection shown below in figure 5.24. Press any of the 3 indicated soft keys to select the gas & range. The <ESC> key will return to the setup menu.

Figure 5.24

5.5.j Conc. Logging (Figure 5.25)

Selecting this menu item will display the screen shown below in figure 5.25. You can select between “All Conc. > 0” (default) and “Alarm Level 1”. Selecting the first choice will cause the system to log all concentrations detected. Selecting the latter will only log concentrations >= Alarm Level 1. The <ESC> key will return to the setup menu.

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Figure 5.25

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5.6 Service Menu

The Service menu is intended for client use but should remain password protected to prevent unauthorized access. The default Service Menu password is included with this manual. The password can be changed as needed (see section 5.6.c)

5.6.a Main Menu

Selecting this menu item will return to the main menu (Section 5.4)

5.6.b Optic Calib (Figure 5.26)

This screen is used to manually calibrate the optics which normally only needs to be done when the system is first configured. Touch the <Start> soft key to start the calibration process. When the process starts the DAC & Ref values will be set to 0. When the process completes both values will update with non-zero values indicating that the process is complete.

Figure 5.26

5.6.c Passwords(Figure 5.27)

This screen is used to change the passwords for both the Setup Menu and Service menu. A password of 0 will disable the password feature for the specified menu. The default passwords are included with this manual.

Figure 5.27

WARNING – Be sure to keep the Service menu password in a safe place. If the service password is lost you will no longer be able to access the service menu and may need to restore default values and completely reconfigure the CL1.

Use the arrow keys below the screen to select among the password fields and enter the values using the procedure outlined in section 5.1.3. The passwords are automatically saved and set to the value displayed.

5.6.d Optic Config

Selecting this menu item will display a screen of values that may aid service personnel in verifying the optic system. Under normal conditions the screen is not used. Hit <ESC> to return to the Service Menu.

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recover the entries after they have been cleared.

5.6.e Status

Selecting this menu item will display a screen of values that may aid service personnel in finding system faults some of which may be edited in the screen. Under normal conditions the screen is not used. Hit <ESC> to return to the Service Menu.

5.6.f Clear History (Figure 5.28)

The history screen contains the 128 most recent event, fault, and alarm messages. Each of the messages logs the date/time occurred and the date/time cleared as separate entries. In the “Event/Alarm History” on the Main Menu (Section 5.4.f) it is not possible to clear the history. By using this screen the history may be cleared if necessary. Use the same procedure used in the alarm and fault screens to clear the entries. Press the soft key next to the arrow then press <F4> to clear. <ESC> will then bring back the screen in 5.28 and <ESC> again to return to the Service menu.

Figure 5.28

WARNING – Clearing the history log is not recommended. There is no way to

5.6.g Configuration

The configuration menu is for certified service personnel only.

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Insert 3/32” Allen

Important:

Maintenance door latch

Service door latches

Service door lock

the Service Door.

Chapter 6 - Maintenance

6.1 Maintenance Door Access

The maintenance door is used to access the ChemLogic tape and the display/keypad. To open the maintenance door release the middle latch on the side of the CL1 as shown in Figure 6.1. When maintenance is complete be sure to close the maintenance door and secure the latch.

The maintenance door should remain securely latched at all times except

when servicing the ChemLogic tape or using the keys on the display.

(tool required)

Figure 6.1

6.2 Service Door Access

DANGER: Service must be performed by trained service personnel

only. Turn off the unit and unplug A/C power to the unit before opening

wrench to remove service door lock .

Figure 6.2

Before opening the service door make sure the maintenance door is securely latched and power is removed. The service door safety lock must be removed with a 3/32” Allen wrench before the service door can be opened.(Figure 6.2) Release the top and bottom latches on the side of the CL1 as shown in Figure 6.1 to open the service door. When service is complete be sure to close the service door and secure all latches on the side of the unit. Then reinstall the service door safety lock and tighten securely.

The service door must remain securely latched with the safety lock installed at all times when not servicing the unit. Verify that both latches are secure and the safety lock is installed to prevent unauthorized access.

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IMPORTANT

: Read Appendix G before handling ChemLogic Cassettes.

6.3 ChemLogic Paper tape

The ChemLogic paper tape has an expiration date printed on the label. Expired tape should be disposed of and replaced with new tape to assure proper gas concentration readings. Each DOD ChemLogic cassette will last for 60 days under normal usage. See Appendix A for ordering information.

ChemLogic Paper Tape Path

Figure 6.2

A. Review the paper tape path shown in figure 6.2 B. Open the maintenance door. (Section 6.1) C. Select Gate & Tape from the main menu (Section 5.4.d)

D. Scroll down with the arrow keys and select “Gate & Tape” E. Touch the <Open/Close Gate> soft key to open the gate.

F. Remove the top tape sleeve with the tape spooled around it by gently pulling away

from the machine.

G. Remove the old tape reel from the bottom spindle by lifting over the washer. H. Discard the old tape & cassette appropriately

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Warning :

I. Remove the new tape reel from the protective packaging.

J. Pull the sleeve off the new tape reel and place the reel on the bottom spindle.

K. Place the new sleeve on the top reel.

L. Feed the new tape through the system as shown in figure 6.2

M. Verify the tape position on all rollers before proceeding.

N. Remove the cover off 1 of the adhesive strips on the take-up reel cover.

O. Press the tape onto the adhesive.

P. Turn the top spindle a full turn to secure the tape

Q. Press the Gate Button several times to make sure the tape is advancing properly. R. On the screen touch the ‘Reset’ soft key. (See section 5.4.d)

6.4 End of line particulate filters

Keep fingers clear during tape advance.

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6.4 End of line particulate filters

End of line (point of detection) particulate filters which protect the CL1 from damage are required for most gases. Table 6.1 details the type of filter required for each gas – Filters must be replaced on a regular basis as shown in the table. Filter orientation is not critical in either application.

Gas

AsH3 Arsine 6 Months 780248

B2H6 Diborane 6 Months 780248 GeH4 Germane 6 Months 780248 H2SE Hydrogen Selenide 6 Months 780248

PH3 Phosphine 6 Months 780248 SiH4 Silane 6 Months 780248 TBA Tertiary-Butyl-Arsine

H2S Hydrogen Sulfide 6 Months 780248 HCL Hydrogen Chloride 1 Month (membrane) 60009 (Housing) 60010 (membrane)

HF Hydrogen Flouride 1 Month (membrane) 60009 (Housing) 60010 (membrane)

BF3 Boron Triflouride 1 Month (membrane) 60009 (Housing) 60010 (membrane)

HBR Hydrogen Bromide 1 Month (membrane) 60009 (Housing) 60010 (membrane)

COCL2 Phosgene 6 Months 780248

Description Suggested Replacement DOD Filter Part #

6 Months 780248

Diisocyanates

NO FILTER N/A

Table 6.1

6.5 Flow adjustment

The pumps in the CL1 automatically adjust to keep a constant flow to the system. No manual adjustment is necessary.

6.6 Micro Secure Digital (SD) Card replacement

See Appendix F for detailed information on the contents of the SD Card.

To install a Micro SD card: Align its 8-pin gold edge connector down, facing the front of the CL1 unit as shown in Figure 6.3; then carefully push it all the way into the Memory slot. Ensure that it clicks into place. To remove the Micro SD card: Push down on the top of the card gently to release the spring. The card pops up for removal. Make sure to format the SD card before first use whenever a new card is purchased.

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Note :

FAT32 file system will not work

Figure 6.3 – Installing Removable Memory Card

When the Micro SD card format was introduced, it was originally called TransFlash. Cards labeled either Micro SD or TransFlash, with up to 2.0 GB of Flash memory, are compatible. The CL1 memory slot is equipped with a “push-in, push-out” connector and a Micro SD card can be safely inserted into the Memory slot whether the CL1 is powered is On or Off.

The CL1 Micro SD Memory slot uses the PC-compatible FAT16 File System. You must format all SD cards before use with the FAT16 format. – See Appendix F.3

Micro SD disks formatted with the

6.4 End of line particulate filters

in the CL1.

Appendix F details the data stored on the SD card and how to access it on a personal computer.

6.7 Fuse Replacement The system power is fused with a 2 amp fast-acting (5x20mm) fuse.

6.8 Apply grease periodically

The cam attached to the gate motor should be greased every 6 months to prevent wear. Apply a small amount of number 2 type petroleum or synthetic grease (such as McMaster Carr

#1378K27) to the rounded portion of the cam. – See Figure 6.4

Top of gate mechanism

Figure 6.4 – Grease may be applied either from the top of the gate mechanism or the bottom.

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Chapter 7 – Service & Support

For information on service and support for your CL1 contact DOD Technologies, INC. using the information below.

Phone Support

M-F 8am – 5pm (Central Time Zone)

815.788.5200

Service Center

740 McArdle Dr. Unit C

Crystal Lake, IL 60014

Visit our website

www.dodtec.com

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Appendix A – Accessories

For ordering information

DOD Technologies, Inc Sales

M-F 8am – 5pm (Central Time Zone)

815.788.5200

DOD Part # Description

1-500-020 CL1 ChemLogic Tape – Diisocyanates (60 days)

Note: Do not use end of line filters

1-300-020 CL1 ChemLogic Tape – Hydrides (60 days)

1-400-020 CL1ChemLogic Tape – Mineral Acids (60 days)

1-200-020 CL1 ChemLogic Tape – Phosgene (60 days)

780248 Disposable non-corrosive end of line filters – Hydrides & Phosgene

60009 Filter housing for use with Teflon membranes for Mineral Acid units 60010 Teflon Membranes – 100 pieces – 47mm

(replacement membrane for use with Part #60009)

2-500-502 Teflon Membranes – 10 pieces – 47mm

(replacement membrane for use with Part #60009)

2-400-007 Tubing FEP 1/4 OD x 1/8 ID x 100' Sample Tubing

Note:All applications except Diisocyanates – 150’ Maximum Sample Length Diisocyanates – 6” Maximum - Sold in 100 foot increments

2-400-008 Tubing Polypro 1/4 OD x 3/16 ID Exhaust Tubing (25 feet)

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Appendix B – I/O Connection Detail

14 pin CL1 I/O connector

Figure B.1

Desription Usage

A System Fault Normally Open B System Fault Common C System Fault Normally Closed

D Gas - Alarm Level 1 Normally Closed

E External Fault&Alarm Reset Momentarily connect to pin N for reset

F Gas - Alarm Level 1 Common G Gas - Alarm Level 1 Normally Open

H 4-20 ma Positive (500 ohm max impedance)

J Ground K 4-20 ma Negative (500 ohm max impedance) L Gas - Alarm Level 2 Normally Closed

M Gas - Alarm Level 2 Common N External Fault&Alarm Reset Momentarily connect to pin E for reset

P Gas - Alarm Level 2 Normally Open

Note : The System Fault relay is energized at all times except when a fault is detected. The

alarm fault relays are configured for energized or de-energized on the Setup Menu.

Note : If the “Positive Pressure Sample Option” is installed, pins L,M,&P can be used to

control a solenoid valve that will activate whenever the pump is not powered.

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Appendix C – Technical Specifications

Physical Dimensions Height 12.5 “ (31.75 cm) Width 10.25” (26.04 cm) Depth 9” (22.86 cm)) Weight 29 lbs. (13.2 kg) Operating Temperature 0 to 40 Degrees Celcius

Flow

Sample Tubing FEP ¼” OD x 1/8” ID (150 ft Max)

Diisocyanates– 6” Maximum FEP ¼” OD Exhaust Tubing ¼” OD x 3/16” ID Polypropylene Pumps 50% duty cycle – long life (2)

Electrical Power 3 Amp Max @ 120v AC (60 Hz) Output Relays 24 VDC 6 Amp Max – 240VAC 6 Amp Max 4-20ma Output 500 ohm load Max External Reset Contact closure (Normally Open)

Misc

Removable Media Micro SD up to 2 GB formatted (FAT16 File System) Noise Level < 15 dB

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Appendix D - System Event Messages

COLOR CODING

RED Alarm Gas Alarm

ORANGE Fault Service Fault

YELLOW Fault Minor Fault

BLUE Event Information Message

GREEN Event Status Update

CL1 Msg

Code Message Possible Cause Corrective Action

1 No Gas Data Loaded System Restored

2 DAC Calibration

Optics Dirty

Required

4 No Gas Selected No Gas Selected

5 Gate Open Fault Motor did not leave home

6 Gate Close Fault Motor did not return

home

7 High Background Fault No Tape Loaded

Optics Dirty

Contact DOD Technnologies support (815) 788-5200

See manual appendix H for cleaning instructions and add a filter to inlet if possible. Also, re-adjust optics - make sure fresh tape is inserted and gate is closed. Then go to service menu-optics and press start.

Select gas in setup menu-select gas option

Make sure that all wires coming from the HMI to the motor are fully inserted(Grey=Q12 and black=ground). Verify belts are all connected and cam is greased. If these steps don't work, contact DOD Technnologies support (815) 7885200

Check issue from "Gate and Tape" screen. If the gate opens and does not stop, there is a problem with the micro swich. Make sure all wires are connected(I8 and V+). Slightly bend the switch arm toward the motor collar to ensure the set screw is closing the switch. If these steps don't work, contact DOD Technnologies support (815) 7885200

Go to "Gate & Tape" and load fresh tape.

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8 Optic Comm Failure Electrical problem

9 All Pumps Disabled Flow Blocked and/or

Unstable Inlet/Exhaust

10 Flow Fluctuation Fault Flow Blocked and/or

Unstable Inlet/Exhaust

11 Idle Timeout Out of Analysis Beyond

Timer

12 Low Background Fault Wrong tape or optic

problem

13 Purge Option Fault Tubing Blocked

14 Optic Auto Cal Failure Optics Dirty

33 SD Card Fault No SD Card or Card Full

34 Analyzing Analysis mode started

35 Chemlogic Tape Low ChemLogic tape nearing

end

36 Pump 1 Disabled Flow Blocked and/or

Unstable Inlet/Exhaust

37 Pump 2 Disabled Flow Blocked and/or

Unstable Inlet/Exhaust

38 Large Flow Fluctuation Flow Blocked and/or

Unstable Inlet/Exhaust

39 High Flow Fault Optics Orifice Dirty

40 Alarm Level 1 Gas Detected

41 Alarm Level 2 Gas Detected

Remove optic block cover and make sure all wires going to the optics are fully inserted. Contact DOD Technnologies support (815) 7885200 if these steps don't correct the problem.

When blockage is fixed, go to Setup Menu and enable pumps. If problem persists, contact DOD (815) 788-

5200. When blockage is fixed, go to Setup

Menu and enable pumps. If problem persists, contact DOD (815) 788-

5200. Re-enter Analysis

Re-adjust optics - make sure fresh tape is inserted and gate is closed. Then go to service menu-optics and press start. If these steps don't work, contact DOD DOD Technnologies support (815)7885200

Find block in sample line

If a SD card is installed remove and re-insert

N/A

Replace tape

Go to Setup Menu and enable pump. If problem persists, contact DOD (815) 788-5200.

When blockage is fixed, go to Setup Menu and enable pumps. If problem persists, contact DOD (815) 788-

5200. See manual appendix H for cleaning

instructions and add a filter to inlet if possible. If problem persists, contact DOD (815) 788-5200.

After gas leak is found and corrected, reset alarms

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42 Remote Reset

43 Power On

44 Optic Calibration Operator initiated

45 Pump 1 high voltage Pump drawing high

current or Bad Pump

46 Pump 2 high voltage Pump drawing high

current or Bad Pump

47 Warning : Optics Dirty Dirty Optics

48 Tape Saver Mode Tape Saver Enabled

49 Hour Diagnostic OK Hourly Checkup

50 Flow Failure 1 L Optics Orifice Dirty

51 Flow Failure 2 L Optics Orifice Dirty

52 Flow Disruption Flow Inconsistent

53 Alarm Level 1 Pt 2 Gas Detected

54 Alarm Level 2 Pt 2 Gas Detected

55 Flow Failure 1 H Sample Inlet Blocked or

Internal Leak

56 Flow Failure 2 H Sample Inlet Blocked or

Internal Leak

N/A

Leak somewhere between the optics and pumps.Check that pumps are connected and all fittings between the optics and the pumps are fully inserted. If problem persists, contact DOD (815) 788-5200.

See manual appendix H for cleaning instructions and add a filter to inlet if possible. If problem persists, contact DOD (815) 788-5200.

N/A

See manual appendix H for cleaning instructions and add a filter to inlet if possible. If problem persists, contact DOD (815) 788-5200.

Contact DOD Technnologies support (815)-788-5200

After gas leak is found and corrected reset alarms

Leak somewhere between the optics and pumps.Check that pumps are connected and all fittings between optics and pumps are fully inserted. Also, make sure all three wires are connected to the transducer. If problem persists, contact DOD (815) 788-5200.

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Appendix E - Gas Specifications

TLV = Threshold Limit Value LAL = Lowest Allowable Alarm Level LDL = Lower Detectable Limit

Full

Family Gas Description Units TLV LAL Scale LDL Default Default Part #

Chlorine CL2 Chlorine ppb 500 125 3200 100 500 1000 1-500-020 DiIsocyanates HDI HDI ppb 5 2 100 1 5 10 1-600-020 DiIsocyanates IPDI IPDI ppb 5 2 100 1 5 10 1-600-020 DiIsocyanates MDI MDI ppb 5 2 100 1 5 10 1-600-020 DiIsocyanates MDI MDI ppb 5 2 200 1.5 5 10 1-600-020 DiIsocyanates TDI TDI ppb 5 2 100 1 5 10 1-600-020 DiIsocyanates TDI TDI ppb 5 2 200 1 5 10 1-600-020

Hydrides AsH3 Arsine ppb 50 12.5 500 6.3 50 100 1-300-030 Hydrides B2H6 B2H6 ppb 100 25 1000 11 100 200 1-300-030 Hydrides H2S H2S ppm 10 0.5 20 0.2 10 20 1-300-020 Hydrides H2S H2S ppb 10000 12.5 90 10 25 50 1-300-020 Hydrides H2S H2S ppb 10000 50 500 13.3 100 200 1-300-020 Hydrides H2S LL H2S ppb 10000 50 1500 13.3 100 200 1-300-020 Hydrides PH3 Phosphine ppb 300 75 1500 11 300 600 1-300-030

Hydrides SiH4 Silane ppm 5 1.2 50 0.8 5 10 1-300-030 LL_Hydrides AsH3 Arsine ppb 5 1 50 0.9 5 10 1-300-020 LL_Hydrides H2Se Hydrogen Selenide ppb 50 12.5 500 5.1 50 100 1-300-020

MineralAcid BF3 Boron Triflouride ppb 1000 250 3200 72 1000 2000 1-400-020 MineralAcid HBR HBR ppm 3 0.7 20 0.2 3 6 1-400-020 MineralAcid HCL Hydrochloric Acid ppm 5 1.2 15 0.2 5 10 1-400-020 MineralAcid HF Hydrogen Flouride ppm 3 0.7 10 0.7 3 6 1-400-020

Phosgene COCl2 Phosgene ppb 100 25 300 3.9 50 100 1-200-020 Phosgene COCl2 Phosgene ppb 100 25 900 6.6 100 200 1-200-020 Phosgene COCl2 Phosgene ppb 100 25 3000 5.2 100 200 1-200-020

Velcorin DMDC Velcorin ppb 40 10 200 8.8 40 80 1-200-040

Amonia NH3 NH3 ppm 25 5 75 1.4 25 50 1-700-020

Alarm 1 Alarm 2 Chemlogic

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Appendix F – Removable Media

To ensure that historical and performance information is stored properly be sure to insert a Micro - Secure Digital (SD) card in the proper slot at all times. See section 6.6 for installation instructions.

The SD card stores all information in standard comma separated values (*.CSV) format for easy access with any computer. Remove the SD card from the CL1 as described in section 6.6 and transfer the files to your personal computer*. The files are best viewed with programs that convert CSV format to rows and columns (Microsoft Excel, OpenOffice, etc) but can be viewed with any text editor.

Figure F.1 shows the folders found on the SD card depending on the configuration or your CL1 and the use of the SD cards. All files have the format YYMMDD.CSV. A new file is automatically created each day – be sure that the Date/Time are set correctly (Section 5.5.e)

Figure F.1

F.1 Concentration Log Files (YYMMDD*.CSV)

Whenever the concentration detected exceeds the preset alarm level in the CL1, the system starts a log file on the SD card (if available). The log file will update approximately every 2 seconds until the gas is no longer detected. A sample alarm file is shown in figure F.2 The columns show: Date, Time, Gas Concentration, Alarm Level 1, Alarm Level 2, and the selected gas range.

Date Time rPtGasConc rPtAlarmLevel1Cu rPtAlarmLevel2Cu nPt1GasIdxCur

09/17/07 04:14:20 PM 107.68 100 200 2

09/17/07 04:14:22 PM 114.41 100 200 2

09/17/07 04:14:24 PM 114.41 100 200 2

09/17/07 04:14:26 PM 119.19 100 200 2

Figure F.2

F.2 Event Log Files (YYMMDD*.CSV)

Each time a new event, fault or alarm is added to the History log on the CL1, the message is written to the current days event log file on the Micro SD card (if available). A sample event log is shown in figure F.3. The columns show: Date, Time, Event Number, and Action (unused). The Event Numbers are listed in Appendix D.

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WARNING

–

Formatting the Micro SD card will erase all information stored on the card.

Date Time nEventNumberCF nEventActionCF

09/17/07 11:07:52 AM 43 1

09/17/07 11:07:52 AM 33 1

09/17/07 11:08:18 AM 48 1

09/17/07 11:08:24 AM 34 1

Figure F.3

F.3 Formatting Micro SD Disks

The Micro SD Cards used in the CL1 must be formatted with the original FAT (FAT16) file system. Most new disks purchased are pre-formatted with FAT32 which will not work in the CL1. The disks may be formatted either from a PC or in the CL1. It is highly recommended that the disk be formatted in the CL1 using the procedure outlined in the following section instead of using a Windows based PC.

Formatting the disk in a MS Windows based PC

WARNING – Make sure to have the correct drive letter for the SD Disk drive. Selecting the

incorrect drive and formatting could result in complete loss of data and/or operation of the computer.

1. Insert the Micro SD card into the SD Card adapter included.

2. Insert the SD card adapter into the correct drive slot on the computer.

3. Open “My Computer”

4. See WARNING above - Right click on the drive letter corresponding to the drive

containing the SD Card adapter. Select ‘Format’ from the drop down menu.

5. Under the heading ‘File System’ select FAT – DO NOT SELECT FAT32

6. Uncheck the “Quick Format” box if it is selected

7. Press Start to format the disk.

8. When complete the disk is ready for use in the CL1.

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Formatting the disk in the CL1

♦ Insert the Micro SD card into the slot. ♦ Wait 5 seconds for the drive to initialize. ♦ Hold in both the “UP” arrow and ‘DOWN’

arrow at the same time which should bring up the screen in figure 2.2.

Figure 2.1

Figure 2.2

Figure 2.3

Figure 2.4

Figure 2.5

♦ Use the down arrow key to scroll down to

the menu item “Removable Media” shown in figure 2.3

♦ Use the <ENTER> key to display the

contents of the Micro SD card as shown in figure

2.4

♦ Press the softkey on the lower right side

which will bring up the screen shown in figure 2.5

♦ Press <F3> to format the disk which will

bring up the screen shown in figure 2.6 .

♦ Press the enter key to begin the format. ♦ When complete press <ESC> several times

to return the CL1 Main Menu.

Figure 2.6

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Appendix G – ChemLogic Cassettes

DOD ChemLogic cassettes are designed for use in colorimetric based gas monitoring systems. Since this is a particular end-use function and does not release or result in exposure to hazardous chemicals under normal use Material Safety Data Sheets (MSDS) are not required.

ChemLogic cassettes are non-toxic and require no special precautions for protection. However contact with skin may cause the cassette to react, change color, and no longer be useful in your gas monitoring system. We therefore recommend that rubber gloves be worn at all times while handling including removal and installation. Always wash hands as a precaution after handling DOD Chemlogic cassettes.

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Appendix H – Optic Block Cleaning Procedure

The CL1 may require periodic cleaning of the optics block when the instrument is used in environments with a high level of airborne particulate or a “High Background” Fault has been reported.

There are two methods for cleaning the optics. One is a basic cleaning using canned air and the other is a more in-depth cleaning of the optics block that requires the optics block back plate be removed.

In most cases the basic cleaning will be sufficient to clear an optics fault and return the DAC to normal operating levels.

Basic Optics Cleaning

1) Exit analysis mode and open the gate and remove the tape.

2) Power down the CL1

3) Use a canned air source to blow into the sample tube inlet as shown in the figure

Figure 1

4) Power on the CL1, enter the “Gate and Tape” mode and reinstall the tape.

5) Exit the tape load screen and enter the “Service Mode”. Use password 1234 to

enter “Service Mode”.

6) Enter “Optic Calib” mode

7) The upper DAC value will be 255 if a “High Background Fault” has been

reported on the CL1.

8) Press the “Start” key and the CL1 will recalibrate the optics. The DAC value

should go down to 140 or below. If it does not, you will need to perform the Advanced Optics Cleaning”.

9) If the DAC value is 140 or below, press “Done”, go to “Main Menu” and clear the

original “High Background” in the “Fault” screen.

10) Exit the “Fault” screen and re-enter analysis.

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Optics Back Plate

Cover

Optics

Back Plate

Advanced Optics Cleaning

1) Exit analysis mode and open the gate and remove the tape.

2) Power down the CL1

3) Remove the optics back plate cover as shown in Figures 3 & 4

Figure 2 Figure 3

4) Remove the Optics Back Plate by removing the two Phillips head screws.

5) Use a canned air supply to blow into channel two of the optics. Channel 2 is 2nd

closest opening to the CL1 as shown in Figure 4. Use the canned air tube to direct flow to both the top and bottom of the optics block.

Figure 4

NOTE: There are two versions of the Optics Back Plate. Rev 2 is displayed in Figure 4. This version of the Back Plate has two holes that align with the posts.

Rev1 Optics Back Plate’s does not have these alignment holes.

6) Re-Install the Optics Back Plate: a. If you have a Rev 2 Optics Back Plate slide the Optics Back Plate onto the

posts and re-install the Phillips head screws.

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b. If you have a Rev 1 Optics Back Plate, re-install the Optics Back plate but

do not tighten the screws.

i. Squeeze the Optics Back Plate and the Optics Block using your

fingers.

ii. Fully tighten the screws while squeezing the blocks together.

7) Power on the CL1 and enter the “Gate and Tape” mode and reinstall the tape.

8) Exit the tape load screen and enter the “Service Mode”. Use password 1234 to

enter “Service Mode”.

Note: Based on the version of software you may be asked to calibrate while exiting the “Gate and Tape” mode. If this occurs, press the “Cancel or NO” choice.

9) Enter “Optic Calib” mode

10) The upper DAC value will be 255 if a “High Background Fault” has been

reported on the CL1.

11) Press the “Start” key and the CL1 will recalibrate the optics. The DAC value

should go down to 140 or below. If it does not, you will need to perform the Advanced Optics Cleaning”.

12) If the DAC value is 140 or below, press “Done”, go to “Main Menu” and clear the

original “High Background” in the “Fault” screen. If not, repeat the process and insure the both the upper and lower channel of the optics block is blown free of particulate.

13) Exit the “Fault” screen and re-enter analysis.

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DOD ChemLogic 1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual