DOD Technologies ChemLogic 4, ChemLogic 8 User Manual

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ChemLogic® 4 & 8

Continuous Gas Monitor User Manual

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CL4 & CL8 Manual

675 Industrial Drive Bldg. A.

Cary, IL 60013

Phone 815.788.5200 • Fax 815.788.5300

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CL4 & CL8 Manual

EC DEC LAR AT ION OF CO NFO RM ITY EU DEC LAR AT ION OF CO NFORM ITY

DOD TECHNOLOGIES INC. 675 Industrial Drive – Bldg. A Cary, IL 60013 USA

Name and address of the company established in European Community and authorized to compile the Technical File

ACC - Services Contact 105 route des pommiers Centre Ubidoca 74370 St Martin Bellevue France

DOD TECHNOLOGIES INC. declares under our sole responsibility that the product described as:

Equipment Name: Continuous Gas Monitor Equipment Description: Detection and measurement of toxic gases Model: CL4/CL8 Serial number(s): _______________

Complies with the requirements of the following European Directives:

Machinery Directive 2006/42/EC; Electromagnetic Compatibility Directive 2014/30/EU. RoHS Directive 2011/65/EU.

Main standards considered :

EN ISO 12100 :2010. EN 50271: 2010. EN 60204-1:2006 +A1:2009. EN 50270: 2006. EN 50581: 2012

Name of authorized company representative: Mr. Daniel O’Donnell

President DOD Technologies, INC

Daniel O’Donnell

Daniel O'Donnell

Date: 05/25/18 At: Cary, Illinois USA

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Table of Contents

Chapter 1 – Overview .................................................................................................................................................................... 7

1.1 Introduction ........................................................................................................................................................................... 7

1.2 Sampling and Monitoring ..................................................................................................................................................... 7

1.3 Flow Connections ................................................................................................................................................................. 7

1.4 Electrical Connections .......................................................................................................................................................... 8

1.5 Theory of operation .............................................................................................................................................................. 8

1.6 Time Weighted Average (TWA) ............................................................................................................................................ 8

Chapter 2 – Features ..................................................................................................................................................................... 9

2.1 External Layout ..................................................................................................................................................................... 9

2.1.1 Warning Labels, Descriptions, & Danger Zones .............................................................................................................. 9

2.1.2 ChemLogic 4 & 8 Danger Zones ..................................................................................................................................... 10

2.1.3 Status Lamp (OPTIONAL) ............................................................................................................................................... 11

2.1.4 Output Wiring Knockouts ................................................................................................................................................ 11

2.1.5 Touch Screen Display...................................................................................................................................................... 11

2.1.6 Keyed Service Door Access ............................................................................................................................................ 11

2.1.7 A/C Power & Switch ......................................................................................................................................................... 11

2.1.8 Flow Adjustment .............................................................................................................................................................. 11

2.1.9 ChemLogic Paper Tape ................................................................................................................................................... 11

2.1.10 Maintenance door.......................................................................................................................................................... 11

2.1.11 Take-up reel ................................................................................................................................................................... 12

2.1.12 Tubing Connections ...................................................................................................................................................... 12

2.2 Maintenance area ............................................................................................................................................................... 12

2.3 Internal Layout – Service area ........................................................................................................................................... 12

2.4 Password Security .............................................................................................................................................................. 13

2.5 USB Memory Stick .............................................................................................................................................................. 14

Chapter 3 – Installation ............................................................................................................................................................... 15

3.1 Selecting a location ............................................................................................................................................................ 15

3.1.1 Lifting Instructions .......................................................................................................................................................... 15

3.2 Mounting ............................................................................................................................................................................. 17

3.3 Sample Tubing .................................................................................................................................................................... 19

3.3.1 Sample Manifold Relocation ........................................................................................................................................... 19

3.3.2 End of line particulate filters ........................................................................................................................................... 19

3.4 Exhaust tubing .................................................................................................................................................................... 20

3.5 A/C Power ............................................................................................................................................................................ 20

3.6 Output Wiring ...................................................................................................................................................................... 20

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3.6.1 Standard Output Relay Module Wiring ........................................................................................................................... 20

3.6.2 Optional 4 to 20ma Output Module Wiring .................................................................................................................... 22

3.6.3 Optional 8 Point Relay Module (Item #2-500-012) ....................................................................................................... 22

Chapter 4 - Setup & Configuration .............................................................................................................................................. 23

4.1 Set system date and time .................................................................................................................................................. 23

4.2 Gas Selection ...................................................................................................................................................................... 23

4.3 Alarm Settings..................................................................................................................................................................... 23

4.4 Output Relays ...................................................................................................................................................................... 23

4.5 Concentration Logging ....................................................................................................................................................... 23

4.6 Install new tape ................................................................................................................................................................... 23

4.7 USB Memory Stick .............................................................................................................................................................. 24

4.8 Setup Complete ................................................................................................................................................................... 24

Chapter 5 – Basic Operation ....................................................................................................................................................... 25

CL4/CL8 Menu Overview .......................................................................................................................................................... 25

5.1 Initialization ......................................................................................................................................................................... 25

5.2 Setup / Main Menu ............................................................................................................................................................. 26

5.2.1 Gas & Alarm Settings Menu ............................................................................................................................................ 27

5.2.2 Set Date/Time .................................................................................................................................................................. 27

5.2.3 Load Tape ......................................................................................................................................................................... 28

5.2.4 Flow Adjustment .............................................................................................................................................................. 29

5.2.5 Calibration Factors .......................................................................................................................................................... 30

5.2.6 Set & Test Outputs ........................................................................................................................................................... 31

5.2.7 Factory Settings ............................................................................................................................................................... 32

5.2.8 Event History .................................................................................................................................................................... 32

5.3 Concentration Log .............................................................................................................................................................. 33

5.3.1 Concentration Configuration .......................................................................................................................................... 33

5.4 Analysis Mode ..................................................................................................................................................................... 34

5.5.1 Point Detail screen .......................................................................................................................................................... 35

5.5 USB Memory Stick log ........................................................................................................................................................ 35

5.6 Time Weighted Average (TWA) .......................................................................................................................................... 36

Chapter 6 – Maintenance ............................................................................................................................................................ 38

6.1 Maintenance Door Access ................................................................................................................................................. 38

6.2 Service Door Access ........................................................................................................................................................... 38

6.3 ChemLogic Paper tape ....................................................................................................................................................... 38

ChemLogic Paper Tape Installation Procedure ...................................................................................................................... 39

6.4 End of line particulate filters .............................................................................................................................................. 40

6.5 Flow adjustment ................................................................................................................................................................. 41

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6.6 USB Memory Stick replacement ........................................................................................................................................ 41

6.7 Apply grease periodically ................................................................................................................................................... 42

6.8 Fuse Replacement .............................................................................................................................................................. 42

Chapter 7 – Service & Support .................................................................................................................................................... 43

Appendix A – Accessories / Cassettes ...................................................................................................................................... 44

Appendix B – I/O Connection Detail ........................................................................................................................................... 46

B.1 Standard Output Relay Module ......................................................................................................................................... 46

B.2 4 to 20mA Module (2 Points per Module) (PN: 2-500-011) ...................................................................................... 47

B.2.1 4 to 20mA Module (4 Points per Module) (PN: 2-500-011) ................................................................................... 48

B.3 8-Point Module (PN: 2-500-012) ...................................................................................................................................... 49

B.4 Optional Mechanical Relays .............................................................................................................................................. 50

B.4.1 Optional Mechanical Relay Wiring ................................................................................................................................. 51

B.5 OPC Interface (PN: 2-500-501) ......................................................................................................................................... 53

Appendix C – System Specifications ......................................................................................................................................... 54

Appendix D – System Event Messages ...................................................................................................................................... 55

Appendix E – Gas Specifications ................................................................................................................................................ 57

Appendix F – USB Memory Stick Data ....................................................................................................................................... 59

F.1 Alarm & Event files (ZG*.CSV) ............................................................................................................................................ 59

F.2 TWA Data Logs (TYYMMDD.CSV) ..................................................................................................................................... 60

F.3 Concentration Log Files (ZL*.CSV) .................................................................................................................................... 60

F.4 Config File ............................................................................................................................................................................ 61

Appendix G – ChemLogic Cassettes .......................................................................................................................................... 62

Appendix H – Optic Block Cleaning Procedure ......................................................................................................................... 63

H.1 Basic Optics Cleaning ........................................................................................................................................................ 63

H.2 Advanced Optics Cleaning ................................................................................................................................................. 64

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Chapter 1 – Overview

1.1 Introduction

WARNING:

Operation of the ChemLogic 8 continuous gas detection system without a manual in the native language in its country of operation is illegal. A translated copy of the manual should be requested immediately from DOD Technologies and before installation of the device. Failure to do so may result in severe injury.

Contact: Phone: +1 815-788-5200 email: [email protected]

The ChemLogic 4 (CL4) & 8 (CL8) continuous gas detection systems should be used exclusively for the quick detection of toxic, corrosive, and asphyxiant gases for process measurement and personnel safety purposes. Failure to comply with the intended purpose of the device may result in injury or death.

The DOD Technologies ChemLogic 4 (CL4) ChemLogic 8 (CL8) simultaneously monitors eight locations

(called points)

for toxic and corrosive gases. It responds to gases that exceed a programmed alarm level by:

• Triggering visual alarms that warn of high or low concentrations

• Triggering relays or activating analog outputs to external devices

• Displaying the point number, gas type, and gas concentration

• Recording the alarm information and storing it in memory

The CL/4CL8 triggers relays for each individual point for two levels of gas concentrations. These programmable limits are factory-set at 1 TLV and 2 TLV for their respective gases.

Each point may be up to 300 feet (91.44 m) from the CL4/CL8 location. This allows operators to monitor gas concentrations in an area removed from the location where gas may actually be leaking.

The CL4/CL8 provides a fast response to a wide range of gases. It was designed for maximum uptime, so routine maintenance and service can be performed quickly and easily.

The CL4/CL8 uses DOD Technologies ChemLogic paper tape technology for fast and accurate gas detection.

1.2 Sampling and Monitoring

The system draws sample flow simultaneously from all eight points. Part of the sample flow is diverted across the ChemLogic tape. All 4/8 channels exhaust through a single port. The ChemLogic 4/8 continuous gas detection system operates at a noise level below 70 dB(A) and does not require hearing protection for operation or work within close proximity. Workplace environment outside the ChemLogic 4/8 system may still require hearing protection. Please consult your safety officer for your recommended safety protocols.

1.3 Flow Connections

Flow connections consist of “quick-connect” ports on the top or side of the CL4/CL8 UNIT. There are eight inlets, one for each monitored point, and an exhaust outlet.

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1.4 Electrical Connections

“Knockout panels” for external electrical connections are provided on the top or right side of the CL4/CL8. The covers are exchangeable to provide top or right-side flexibility.

1.5 Theory of operation

The system draws sample flow simultaneously from all four/eight points. Part of the sample flow is diverted across the ChemLogic Tape. The ChemLogic 4/8 uses an advanced optical detection system to measure the light level reflected from the ChemLogic tape. As the target gas is detected, the color of the of the ChemLogic tape changes. This color change results in a loss of reflected light across the ChemLogic tape. This loss of reflected light is detected by the advanced optics system in the ChemLogic 4/8. The ChemLogic 4/8 will then report an appropriate gas concentration reading and/or a gas alarm.

1.6 Time Weighted Average (TWA)

During analysis the CL4/CL8 stores the TWA information every 8 hours* (referred to as a ‘cycle’). The system retains the 5 most recent cycles in memory and will save all cycles to the CUSB Memory Stick – if installed. The number of cycles capable of being stored on the USB Memory Stick is only limited by the size of the USB Memory Stick.

*NOTE: If analysis is stopped by the operator or due to any other factor (critical

service fault, power interruption, etc.), the TWA information is saved as a separate cycle regardless of how much time has elapsed since the cycle started.

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Chapter 2 – Features

2.1 External Layout

Figure 2.1

2.1.1 Warning Labels, Descriptions, & Danger Zones

The below table references all warning labels and their meanings that may be encountered while operating and servicing the ChemLogic 4 and 8 continuous gas detection equipment.

WARNING:

Hot Surface. This surface will be hot to touch and may cause injury. Please avoid or take caution when working near this zone.

WARNING:

Protective Earth Ground. Terminal Intended for connection to external conductor for protection against electric shock in case of fault.

ATTENTION:

Please read operators manual for all instruction for this machine. If manual is not in country’s native language, requested updated manual before use of equipment.

Output Wiring Knockouts

Keyed Service Door Handle

A/C Power & Switch

Flow adjustment knobs

ChemLogic Tape

Maintenance Door

Take-up reel

4 color status lamp and audible alarm (Optional)

Flow tubing & exhaust quick connect system

Touch Screen LCD Display

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WARNING:

Electric Shock is possible, please use caution when accessing this zone.

WARNING:

Moving Parts and Hand Crushing possible. Please watch hand placement when working near this zone.

2.1.2 ChemLogic 4 & 8 Danger Zones

Please be aware of the following danger zones on the ChemLogic 4 and 8 continuous gas detection equipment. Each zone contains warning labels for operator safety. Label meanings/descriptions can be found in the above table

This danger zone is in the service access point of the unit. Users should be aware of hot surfaces and electrical shock.

This danger zone is located on the gate assembly. During operation, operators could pinch fingers if not aware of hand placement.

This danger zone is located on the right exterior of the unit. This area warns of electrical shock areas within the service door of the machine.

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2.1.3 Status Lamp (OPTIONAL)

The optional status lamp consists of 4 colored lights – Red, Orange, Blue, and Green along with an audible alarm. See Appendix A for ordering information.

2.1.4 Output Wiring Knockouts

There are two knockouts available for output wiring located on the top panel near the right side and on the right-side panel near the top.

2.1.5 Touch Screen Display

The CL8 uses a full color touch panel LCD display. All menus and data entry are accomplished by touching the appropriate area of the screen – see Chapter 5 “Basic Operation”.

2.1.6 Keyed Service Door Access

The door uses a key lock to restrict internal access. See section 2.3 for detailed information on the service area.

2.1.7 A/C Power & Switch

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

2.1.8 Flow Adjustment

Flow adjustments for all 4/8 points are located on the front panel. Refer to section 5.2.d regarding flow adjustment.

2.1.9 ChemLogic Paper Tape

ChemLogic paper tapes are accessed by opening the maintenance door. Refer to section 6.3 regarding tape installation/replacement.

2.1.10 Maintenance door

The maintenance door allows easy access to the ChemLogic tape for installation and replacement.

IMPORTANT: The maintenance door should remain closed and latched except

when changing the ChemLogic tape. Do not open the door while in Analysis Mode.

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2.1.11 Take-up reel

An empty take-up reel is inserted at the time of ChemLogic tape installation (see section 6.3). During installation the previous take-up reel which is full is removed from CL4/CL8 and discarded. The previous ChemLogic tape reel which is now empty should then be used as the next take-up reel.

2.1.12 Tubing Connections

Sample tubing and exhaust use a quick connection system for simple installation. The connections may be made on either the top or left side of the CL4/CL8. See section 3.3 for information on connecting the sample and exhaust tubing. See also Appendix C for essential information on transport times for gas from sampling point to the CL4/CL8.

2.2 Maintenance area

The maintenance area allows easy access for changing ChemLogic tape in the CL4/CL8. Figure 2.2 shows the internal layout with the access panel open. See section 3.5 for tape installation.

Figure 2.2

2.3 Internal Layout – Service area

Internal access to the CL4/CL8 for installation and service uses the keyed handle located on the right side of the front panel. Figure 2.3 shows the internal layout of the CL4/CL8 with the service door open.

IMPORTANT: End of line filters are required at all times on each channel – see

Section 6.2.

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

Figure 2.3

2.4 Password Security

Access to many of the features is controlled through password protection which is entered through the screen displayed in figure 2.4.

Figure 2.4

DANGER: Turn off the unit and disconnect unplug A/C power to the

unit before opening the Service Door.

Inside w/Service Door open

Back of Service Door

(OPTIONAL) 4-20ma

Output Connection

USB Memory Stick Access

Pump

Power Supply

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Whenever someone attempts to access a screen that is password protected, the screen shown in figure 2.2 will appear (see important note below). Several of the setup & configuration screens of the CL4/CL8 require entry of an administrative password. Factory service screens require entry of a service password - see section 7.

NOTE: The Administrative Password is included on the first page of this manual. It is suggested that you

remove the page and keep in a safe and secure place. If you forget or lose your password please contact DOD Technologies, INC. See Chapter 7 for contact information.

2.5 USB Memory Stick

The CL4/CL8 uses a USB Memory Stick to store historical information including concentration logging, event history, configuration information, and TWA data. The use of higher speed USB Memory Stick (2x, etc.) may not be compatible with the CL4/CL8. USB Memory Sticks may be purchased through DOD Technologies – see Appendix A.

IMPORTANT: Once a password is entered it remains active for 2 minutes after

entry so that it does not need to be repeatedly entered when switching between screens. Please remember that anyone using the touch screen may access restricted screen locations during this time if the machine is left unattended.

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Chapter 3 – Installation

3.1 Selecting a location

The CL4/CL8 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 300 ft. Using the shortest possible sample line length will reduce

transport times and increase the response time of the CL4/CL8. (see Appendix C)

• 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 CL4/CL8 requires stable temperature and humidity levels within range to operate properly.

Recommendations

Do not place in a location which will expose the CL4/CL8 to moisture, dust, corrosive gas, or any unusual environmental conditions which could damage the unit and/or cause it to operate inaccurately.

3.1.1 Lifting Instructions

It is recommended that installation of this unit requires the help of 3 individuals. Two individuals should lift the unit into its desired location while the third person secures the device into a mounted position. If the device must be manually handled, follow the following steps each time:

1. Size up the Load

• Check if the weight of the object is listed on it

• If not, push, pull, gently kick or rock the object to be moved before you attempt to move it – get a feel

for its weight, size and shape

• Check whether the weight is evenly distributed

• Recognize what your own limits are and stick to these limits

Ensure the area is clear

• Work out where the load is going

• Ensure that your intended pathway is clear and free of obstacles

• Make sure that your vision will not be blocked when moving large objects

Position your feet correctly

• Place your feet a comfortable distance apart (shoulder width). A broader base of support increases

stability. With a narrow base of support with your feet too close together, you are more likely to lose your balance.

• Point your feet in the direction that you intend to travel

• Always turn with your feet, not your hips or shoulders. Never twist as you move or go to lift!

Get as close to the load as possible

• Walk over to the load – don’t stand still and reach for it

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Maintain the normal curves in your spine You need to try and work in your power zone – above your knees and below the shoulders

• Keep the back straight and the head looking up

• Half bend the knees and use your leg muscles

• Bend forward at the waist

• Stick your bottom out

• Bend your back as little as possible Keep your head looking up, not down

• Put weight down through your heels, not the toes

Use the correct grip

• Have a firm grip by using the palms and the base of the fingers Don’t just use your fingertips as this

can cause strain on the hands, wrists and forearms

Lift Smoothly

• Grip the load firmly and hold it close to your body. Keep the heaviest side closest to your body.

• Brace’ (tighten) your stomach muscles. Remember to breathe out when you lift. However, remember

that bracing the stomach muscles does not mean ‘holding your breath’.

• Thrust with the legs - Use the leg muscles to move the load (quadriceps and gluteal muscles).

• They are much bigger and stronger than the back muscles .

• Complete the movement smoothly and without jerkiness.

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3.2 Mounting

Figure 3.1

Front

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Figure 3.2

Figure 3.4

Top

Right

Side

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Refer to figure 3.1 for dimensional requirements for wall mount. Be sure the CL4/CL8 is properly secured to the wall.

3.3 Sample Tubing

Sample tubing may be connected to the CL4/CL8 on the top or left side of the CL4/CL8 (see section 3.3.1). All

sample tubes are 1/4” OD x 3/16” ID Teflon FEP (300 ft max length) which may be purchased from DOD

Technologies, INC (See Appendix A). Fully depress each sample tube into the proper hole when attaching. To detach the tube, push on the collet and pull the tubing out

3.3.1 Sample Manifold Relocation

The quick connect system used to attach sample tubing and exhaust may be located on the top or left side of the machine. To move the manifold, Follow the procedures in section 6.2 to open the service door.

• Remove the four (4) mounting screws shown in figure 3.5 to detach the manifold.

• Remove the 4 lock nuts holding the cover plate over the unused manifold opening

• Remove the cover plate

• Align the manifold inside the CL4/CL8 with the holes in the new position

• Replace the screws holding the manifold in place and tighten accordingly.

• Replace the cover plate over the unused opening and secure with the four lock nuts.

Figure 3.5

Sample tubing may be purchased from DOD technologies (see appendix A)

3.3.2 End of line particulate filters

End of line particulate filters must be installed on all 4/8 sample lines at all times to prevent damage to the unit. Unused lines must either be plugged or have a filter installed. Filters require regular maintenance – see chapter 6.

IMPORTANT: All sample tubing used with the CL4/CL8 must be 1/4”OD x 3/16”

ID FEP Teflon. Use of any other tubing may damage the CL4/CL8 and/or cause inaccurate gas concentration readings.

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

3.4 Exhaust tubing

The exhaust line must be 3/8” OD x 1/4” 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 CL4/CL8. Longer cords are available from most electrical supply stores.

3.6 Output Wiring

Figure 3.2 details the connection method for both the standard relay output module and the optional 4 to 20 ma modules.

See Appendix B for a listing of output module connections.

3.6.1 Standard Output Relay Module Wiring

The standard output module requires an external 24V supply connected to V1+/- and V2+/- (see Appendix B). Outputs 0-15 are powered through V1 while outputs 16-31 are powered through V2. Each output can handle up to 0.2 Amps with a total maximum current of 1.6Amps to each group of 16 outputs at any time. See figure

3.6 and 3.7 for information on wiring the CL4/CL8 standard relay outputs.

IMPORTANT: All points require filtration to prevent dust accumulation in tubing and

internal damage to the CL4/CL8. Dust that collects in the tubing or the internal system may cause sample loss and inaccurate gas concentration readings.

Wiring knockouts on sides of cabinet

Service

Door

Open

DOD 4 to 20ma Module 1

DOD 4 to 20ma Module 2

DOD Output Relay

Module

Pump

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Figure 3.6

Figure 3.7

Use only AWG22 to AWG18 twisted wire (wire sizes UL1015 and UL1007) Strip from .26” to .31” (6.5mm to 8.0mm) from each wire to insert into the connector.

1. To connect the wires to the spring-loaded output connector:

2. Insert the screwdriver into the square shaped hole which will open the round hole for the wire.

3. Continue to hold the screwdriver while inserting the wire into the round shaped hole.

4. While holding the wire in place remove the screwdriver which closes the clamp onto the wire.

5. IMPORTANT: Be sure the wire is inserted completely into the hole. Failure to do so could result in

system failure, electrical shock.

6. To remove a wire, re-insert the screwdriver in the hole as described in step 1 and gently pull the wire

out while the spring is compressed.

V1 +

V1 -

LOAD

+ 24V -

…

OUT 0

OUT 15

LOAD

V2 +

V2 -

LOAD

+ 24V -

…

OUT 16

OUT 31

LOAD

DANGER: Before performing any wiring modifications, be sure that

power to the CL4/CL8 is disconnected and remove the output connector from the output relay block.

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3.6.2 Optional 4 to 20ma Output Module Wiring

Figure 3.8 details a typical connection to one of the eight (8) 4 to20ma output connections. See Appendix B for a complete list of terminal connections on the optional 4 to 20ma output block.

Figure 3.8

3.6.3 Optional 8 Point Relay Module (Item #2-500-012)

See Appendix B for a complete list of terminal connections on the optional output block.

IMPORTANT: Verify that all I/O unit terminal screws are securely tightened even if

they are not used.

DANGER: Before doing any wiring, modifications be sure that power

to the CL4/CL8 is disconnected.

IMPORTANT: Verify that all I/O unit terminal screws are securely tightened even if

they are not used.

DANGER: Before doing any wiring, modifications be sure that power

to the CL4/CL8 is disconnected.

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Chapter 4 - Setup & Configuration

4.1 Set system date and time

See section 5.2.2

4.2 Gas Selection

Each point on the CL4/CL8 must be setup for the appropriate gas and configured accordingly. See section

5.2.1 for information on selecting the gas for each point.

4.3 Alarm Settings

See section 5.2.a for information on how to adjust the alarm settings after the gas has been selected for each point.

4.4 Output Relays

The CL4/CL8 supports both energized and de-energized relays and may be configured for either latching or non-latching faults/events.

When configured for energized relays, the outputs are normally in a high state and change to a low state when the corresponding fault / alarm occurs. De-energized relays work in the opposite manner. See section

5.2.f. When the power is ON, the Power Loss relay is always in the normally high state.

When latched outputs are selected (section 5.2.f), any fault or alarm that occurs will remain until the ‘fault reset’ button is touched. If non-latching outputs are selected the output will reset automatically if, and when, the condition that caused the fault/alarm goes away.

NOTE: A message is added to the event log each time the ‘fault reset’ button is touched.

4.5 Concentration Logging

Three levels of concentration logging can be configured in the CL4/CL8.

1. >0 - All concentrations detected >= LDL are added to the concentration log.

2. AP1 - Anytime alarm level 1 is reached, the concentrations are added to the log.

3. AP2 - Anytime alarm level 2 is reached, the concentrations are added to the log.

Regardless of which point the gas is detected on, all CL4/CL8 points are logged as long as the trigger is active. For AP1 or AP2 logging the system will continue to log concentrations as long as the alarm level is active. If latching faults are enabled the system will continue to log until the ‘fault reset’ button is touched. See section 5.3

4.6 Install new tape

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See section 6.3 for installation instructions.

4.7 USB Memory Stick

The use of a USB Memory Stick is highly recommended to retain historical and performance information including events, alarms, and gas concentrations. USB Memory Sticks are available from DOD technologies (see Appendix A) and at most retail electronic stores. See section 6.4 for information on inserting and replacing a USB Memory Stick. See also Appendix F for information on the data stored on the USB Memory Stick.

4.8 Setup Complete

Enter analysis.

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Chapter 5 – Basic Operation

CL4/CL8 Menu Overview

I. Initialization (Power on) (sec. 5.1)

a. Setup Mode b. Timer

II. Setup (11 button menu) (sec. 5.2)

a. Gas & Alarm Settings

i. Points 1-4

ii. Points 5-8 b. Set Date/Time c. Load Tape d. Adjust Flow

e. *Calibration Factors f. *Set/Test Outputs

g. **Factory Settings

h. Events History i. Fault Reset j. Start Analysis

III. Concentration Log (sec. 5.3) IV. Analysis (5 buttons & 8 points w/detail) (sec. 5.4)

a. Setup b. Concentration Log c. Event History d. Silence e. Fault Reset f. Point Detail (1-8)

V. USB Memory Log (sec. 5.5)

VI. Time weight average (sec. 5.6)

Legend

User Screens

(No Password Required)

*Administrative Screens

(Administrator Password Required)

**Service Screens

(Service Password Required)

5.1 Initialization

When the CL4/CL8 is powered on it will begin with an initialization screen (figure 5.2) which is followed by the restart screen (figure 5.3).

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Figure 5.2 Figure 5.3 If the operator touches the ‘SETUP MODE’ button before the timer reaches 0 the Setup screen appears (section 5.2) otherwise after a timeout the system will start analysis (section 5.4)

5.2 Setup / Main Menu

The setup menu is accessed either by touching the ‘SETUP MODE’ button on power up (section 5.1) or by touching ‘SETUP’ from the analysis screen (section 5.5). Figure 5.4 below shows the setup screen and

explains the various buttons.

Figure 5.4

View/Reset tape usage counter. (Section 5.2.c)

Set system Date & Time (section

5.2.b)

Touch to reset all

active faults &

alarms.

Touch to Start Analysis (Section 5.5)

Touch to

display version and configuration

information.

Service password

required

Flow adjustment – (section 5.2.d)

Gas selection

and alarm level settings (Section 5.2.a)

Adjust Calibration

Factors

(Section 5.2.e)

Set latching outputs and

test outputs.

(Section 5.2.f)

View alarms, system

events, conc. Log, and other files on USB Memory Stick.

(Section 5.2.h)

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5.2.1 Gas & Alarm Settings Menu

Touching the ‘GAS & ALARM SETTINGS’ button on the setup screen brings up the screen shown on the left in figure 5.5 which displays the configuration of points 1-5. Touching the ‘NEXT’ button will bring up the screen shown on the right of figure 5.5 which displays the configuration of points 5-8. Touching the ‘BACK’ button will then return to the SETUP screen.

Figure 5.5

Touching the ‘CHANGE GAS’ button brings up the gas selection menu from which you may either select a new gas or touch the ‘Cancel’ button. Touching any of the alarm level numeric displays will bring up the keypad to

change the alarm level. The valid alarm levels are listed in Appendix X for each gas. An invalid alarm level entry will bring up an error message.

The toggle switch to the right of each point allows the individual points to be disabled when not in use. The word ‘DISABLED’ will then appear on the analysis screen for that point and no calculations will be made.

5.2.2 Set Date/Time

Touching the ‘SET DATE/TIME’ button on the setup screen brings up the screen shown in figure 5.6.

Next for points 5-8.

Touch ‘CHANGE GAS’ to

bring up selection menu.

Touch the Alarm Level # to change.

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Figure 5.6

Touching any of the numeric displays for Month, Day, Year, and Time will bring up the numeric entry keypad. The time must be entered in 24-hour (Military) time format. Touch the ‘BACK’ button to return to the setup menu.

5.2.3 Load Tape

Touching the ‘LOAD TAPE’ button on the setup screen brings up the screen shown in figure 5.7.

Figure 5.7

IMPORTANT: After entering the new date & time you must touch the ”Apply

Changes” button to update the system date/time.

Touch to reset tape counter

after installation

Enable/Disable Tape Days remaining counter & fault.

Open & Close gate as

needed to install tape.

To exit screen you must press this button to verify

IMPORTANT: Each time a new tape is loaded into the CL4/CL8 the ‘RESET

COUNTER’ button must be touched to accurately track tape usage.

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Each time the ‘OPEN/CLOSE GATE’ button is touched, the gate will open or close appropriately. If the gate is currently closed, touching the button will open the gate. If the gate is currently open* touching the button will close the gate.

To Exit the screen optics verification is required. When the ‘Verify Optics’, button is touched the machine will verify the tape is aligned correctly and the optics are calibrated appropriately. During this time a ‘ONE MOMENT PLEASE’ window will appear. When verification is complete one of the two screens in figure 5.8 will appear.

Figure 5.8

If successful touch the “OK” button to return to the setup menu. If unsuccessful verify that the tape is installed and aligned correctly by using the ‘OPEN/CLOSE GATE’ button as needed. Once you have verified that the tape is installed correctly you can touch the ‘YES’ button to recalibrate the optics for the new tape or press ‘NO’ to return to the setup menu.

5.2.4 Flow Adjustment

Touching the ‘ADJUST FLOW’ button on the setup screen brings up the screen shown in figure 5.9 along with

advancing the tape and turning the pump on. Use the corresponding flow adjustment knobs located on the front panel to adjust the flow so that each level is as close as possible to the black line in the middle of the green section.

NOTE: If the gate is not completely open touching the button will open the gate to

the proper open position. Touch the button again to close.

IMPORTANT : If you choose ‘NO’ when asked to calibrate the optics as shown to

the right of figure 5.8 the CL4/CL8 may not function properly. Contact DOD Technologies for more information.

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Figure 5.9

Touch the ‘BACK’ button to return to the setup menu.

5.2.5 Calibration Factors

Touching the ‘CALIBRATION FACTORS’ button on the setup screen brings up the screen shown in figure 5.10 This screen requires administrator password access. Contact DOD (see chapter 7) for information on the use of Calibration Factors.

Figure 5.10

*NOTE: There may be a slight delay between the time the knob is turned, and the updated reading is reflected on the screen. Adjust the knob slowly and wait a few seconds to verify that the level is accurate.

Adjust flow to this level.

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Touching any of the numeric displays for any of the channels will bring up the numeric entry keypad. The value entered must be between 0.5 and 2.000 for each channel.

5.2.6 Set & Test Outputs

Touching the ‘SET/TEST OUTPUTS’ button on the setup screen brings up the screen shown in figure 5.11.

This allows the user to test relays and analog outputs. Two other features on this screen:

1. Require a password to exit analysis – If enabled the level 1 password must be used for anyone to exit

the analysis screen. When disabled a simple “Are you sure?” window appears.

2. Idle Timeout – Set from 1-60 minutes to trigger a fault when the machine is left in idle. Setting this to

0 minutes disables the fault.

Figure 5.11

NOTE: This screen requires the Administrator password for access – See section

2.4

CAUTION: Activating these outputs will trigger any connected alarms

Output Relay Test

Alarm Relay Test

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5.2.7 Factory Settings

This button is reserved for technical service and requires a service password. Contact DOD Technologies, INC (section 7) for service information.

5.2.8 Event History

Touching the ‘EVENT HISTORY’ button on the setup screen brings up the screen shown in figure 5.11.

Figure 5.12

The event history is display with the most recent event/alarm at the top using the color coding listed in table

5.1.

Table 5.1

Green

Normal operation messages

Yellow

Fault messages

Blue

Informational display messages – non-critical

Orange

Critical Service messages

Red

Gas alarm messages

Touch the ‘BACK’ button to return to the setup menu.

Touch inside this message area and

then use the green up and down arrows to scroll the screen. Most recent

messages appear on top.

Reset active faults & alarms.

See section 5.3

See section 5.5

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5.3 Concentration Log

Touching the ‘CONC LOG’ button on the Event History screen (section 5.2.9) will bring up the screen shown in figure 5.13.

Figure 5.13

The log displays the concentration on each point when the trigger criteria is met. If you select >0 the system will log all CL4/CL8 points when any of the points have a concentration reading which is >LDL for the gas selected. (See appendix E). The buttons on the right of the screen allow scrolling through the most recently logged readings. Touch the configuration button to set the logging parameters.

5.3.1 Concentration Configuration

Figures 5.12.b shows the concentration configuration screen. Four levels of logging area available depending on your needs.

1. Alarm Level 2 – Logging on when any channel is above alarm level 2

2. Alarm Level 1 – Logging on when any channel is above alarm level 1.

3. 0 – Logging on when any channel is above 0

4. Continuous – Logging always on (not recommended)

Figure 5.12b

Page Up

Up 1 message Go to last message

Down 1 message

Page Down

See section 5.5

Current

log file name

Go to Concentration configuration Page (See section

5.3.1)

See section 5.6

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In addition, the logging interval can be adjusted from the default of 2 seconds to a maximum of 10 minutes (600 seconds).

5.4 Analysis Mode

Figures 5.13 shows the main analysis screen which is entered either automatically during power on or by touching the ‘START ANALYSIS’ button on the setup screen. Figure 5.14 shows the main analysis screen with a detailed view of the information on point 3.

Figure 5.13

Figure 5.14

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At the bottom of the analysis screen on the right side is the current date & time and a message box below it. The message box will either display the blinking message ‘NO USB Memory Stick or will be blank if a USB Memory Stick is inserted in the machine. (See section 2.5.)

To display detailed information on any point touch along the left-hand side from the point # to the square box above it which will bring up the point detail screen (section 5.5.1).

Touch the ‘BACK’ button to return to the setup menu.

5.5.1 Point Detail screen

Touching a point # on the analysis screen (Section 5.4) will bring up the point detail screen shown in figure

5.15

Figure 5.15

The information on the point detail screen is updated in real time while in analysis mode. Alarm levels may be changed by touching the numeric display area for the appropriate alarm. Similarly, the comments related to this point may be edited by touching anywhere in the box displayed for comments.

5.5 USB Memory Stick log

Figures 5.16 shows the ‘CF Log’ which is displayed by touching the ‘CF Files’ button on the concentration log

(Section 5.3). This screen allows the user to browse everything contained on the USB Memory Stick currently inserted. (Note – if no USB Memory Stick is present or there is an error reading the card, the left selection screen will appear blank). To initiate the display touch ‘DISP’.

Gas

and full scale

range

User entered comments

Trend graph of gas concentration on this

Current alarm limits for this point.

Current concentration

Current Flow Setting

Point disabled message

NOTE: The display of the current flow may not be immediately displayed on this

screen. It is recommended that the flow adjustment screen (section 5.2.4) be used for all flow calibration.

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Figure 5.16

5.6 Time Weighted Average (TWA)

Touching the ‘TWA’ button on the concentration log screen (section 5.3) brings up the TWA screen shown in

figure 5.17.

Figure 5.17

List of items in

current folder w/current selection

highlighted.

Touch ‘DISP’ to

display contents of

selected folder or

Delete selected

Arrow keys to scroll through list

Use these

keys to navigate when viewing a

file.

TWA information for current analysis cycle.

Use the arrow keys to

scroll through the previous 5 analysis

cycles.

Details of selected analysis cycle. Start & End

Date/Time, actual analysis time, and cycle

number (sequencial #).

Peak value reached in current cycle

Highest 15 minute average reached including

date/time of occurrence.

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The first screen displays the current TWA information including the minutes and seconds elapsed since the cycle started. The CL4/CL8 retains the most recent 5 analysis cycles (up to 40 hours) in addition to the current cycle in memory. The previous cycles are accessed by touching the ‘View History’ button which brings up the screen shown in the lower right of figure 5.17. Use the up and down arrows to review the previous 5 cycles in this screen.

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Chapter 6 – Maintenance

It is recommended for complete safety that the ChemLogic 4/8 continuous gas detection system be serviced on-site every 6 months by a certified DOD Service Engineer or by submitting the unit to the manufacturer for routine maintenance. A certificate of repair should be received and kept with operation documents of the machine. Any malfunctions in the device should be reported and corrected before further use.

6.1 Maintenance Door Access

The maintenance door is used to access the ChemLogic tape. To open the maintenance door simply turn the maintenance door locking knob counterclockwise until it is unscrewed from the main panel. The door can then be opened.

When maintenance is complete be sure to close the maintenance door and hand tighten the maintenance door locking knob (clockwise) to secure the door.

6.2 Service Door Access

To open the door:

1. Insert the key provided into the slot and rotate counter clockwise to unlock the unit.

2. Turn the latch counterclockwise to unlatch the door.

3. Open the door for service as required.

When service is complete be sure to close the service door and secure the keyed latch to the closed position. Verify that the service door cannot be pulled open – secure the door using the key to lock the door.

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 tape cartridges will last for 60 days under normal usage. See Appendix A for ordering information.

IMPORTANT: The maintenance door should remain securely latched at all times

except when servicing the ChemLogic tape.

DANGER: Turn off the unit and unplug A/C power to the unit before

opening the Service Door.

IMPORTANT: The service door must remain securely latched at all times when not

servicing the unit. Verify that the latch is secure and use the keyed lock to prevent unauthorized access.

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ChemLogic Paper Tape Installation Procedure

A. From the setup menu touch the ‘Load Tape’ button (section 5.2.3) B. Open the maintenance door. (Section 6.1) C. On the screen touch the ‘OPEN/CLOSE GATE’ button to open the gate D. Remove the old take-up reel by gently pulling and dispose of properly E. Remove the empty tape reel and install on top as the new take-up reel. F. Secure the new ChemLogic tape reel on the bottom as shown in figure 6.1. The tape should be around

the bottom in a clockwise direction as shown.

G. Feed the tape as shown with the arrows in figure 6.1.

1. From the bottom reel

2. Around the bottom tape guide

3. Through the opening between the optic blocks

4. Between the rubber roller and the capstan

5. Around the top of the upper tape guide

6. Fold the end of the tape and insert into the slot in the empty tape reel. Be sure the tape is wound

clockwise around the take-up reel.

Figure 6.1

H. Turn the upper wheel clockwise at least 2 full turns to secure the tape I. On the screen touch the ‘OPEN/CLOSE GATE’ button to close the gate J. On the screen touch the ‘Reset Counter’ button. (See section 5.2.3)

Warning: Keep fingers clear during tape advance.

Upper tape reel

1 2 3

5 6

Lower tape reel

Optic Blocks

Bottom tape guide

Top tape guide

Capstan / Rubber roller

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6.4 End of line particulate filters

End of line (point of detection) particulate filters which protect the CL4/CL8 from damage are required on all 4/8 points including points not being monitored. Table 6.1 details the type of filter required for each gas – see also figure 6.2. Filters must be replaced on a regular basis as shown in the table. Filter orientation is not critical in either application.

Table 6.1

Gas

Description

Suggested Replacement

DOD Filter Part #

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

6 Months

780248

H2S

Hydrogen Sulfide

6 Months

780248

HCL

Hydrogen Chloride

1 Month (membrane)

60009 (Housing) 60010 (membrane)

2-800-013

Hydrogen Fluoride

1 Month (membrane)

60009 (Housing) 60010 (membrane)

2-800-013

BF3

Boron Trifluoride

1 Month (membrane)

60009 (Housing) 60010 (membrane)

2-800-013

HBR

Hydrogen Bromide

1 Month (membrane)

60009 (Housing) 60010 (membrane)

2-800-013

COCL2

Phosgene

6 Months

780248

IMPORTANT: All points require filtration to prevent dust accumulation in tubing and

internal damage to the CL4/CL8. Dust that collects in the tubing or the internal system may cause sample loss and inaccurate gas concentration readings.

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Mineral Acids Filter

Part Numbers: Blue Housing: 60009 Filter Membrane: 60010

Hydrides & Phosgene Filter

Part Number: 780248

Mineral Acids Disposable Filter

Part Number 2-800-013

Figure 6.2

6.5 Flow adjustment

Each channel should be adjusted whenever a new ChemLogic tape or particulate filter is installed. See section 5.2.4

6.6 USB Memory Stick replacement

It is highly recommended to keep a USB Memory Stick inserted in the unit at all times. The lower right corner of the analysis screen will show when a card is properly inserted (see section 5.4) To insert or replace a USB Memory Stick follow these steps below.

1) Locate USB slot on middle center of the HMI. It is marked USB.

2) Removal: a) Pull USB Memory Stick straight down

3) Insertion:

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a) Push the USB Memory Stick straight up ensuring the USB Memory Stick and slot are aligned properly.

Figure 6.3 Section 5.5 describes viewing the files stored on the USB Memory Stick on the touch screen. Appendix F details the data stored on the USB Memory Stick and how to access it on a personal computer.

6.7 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

Bottom of gate mechanism

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

6.8 Fuse Replacement

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

DO NOT REMOVE

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Chapter 7 – Service & Support

For information on service and support for your CL4/CL8 contact DOD Technologies, INC. using the information below.

For Permanent discontinuation: Please contact DOD Technologies for the safe return of your equipment. All discontinued units will be accepted back by DOD Technologies so proper recycling may take place. For information on how to return the unit contact us using the below information:

Phone Support M-F 8:30am – 5pm (Central Time Zone)

815.788.5200

Service Center 675 Industrial Drive Bldg. A. Cary, IL 60013

Visit our website

www.dodtec.com

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Appendix A – Accessories / Cassettes

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Appendix B – I/O Connection Detail

B.1 Standard Output Relay Module

Description

Output

Point 1 Alarm Level 1

Point 1 Alarm Level 2

Point 2 Alarm Level 1

Point 2 Alarm Level 2

Point 3 Alarm Level 1

Point 3 Alarm Level 2

Point 4 Alarm Level 1

Point 4 Alarm Level 2

Point 5 Alarm Level 1

Point 5 Alarm Level 2

Point 6 Alarm Level 1

Point 6 Alarm Level 2

Point 7 Alarm Level 1

Point 7 Alarm Level 2

Point 8 Alarm Level 1

Point 8 Alarm Level 2

Critical Fault

Watchdog

Power On

Analysis Mode

General Fault

Gas Alarm Level 1

Gas Alarm Level 2

Critical Fault (*)

General Fault (*)

Gas Alarm Level 1 (*)

Gas Alarm Level 2 (*)

Blue Light

Audible Alarm

Green Light

Orange Light

Red Light

(* ) Can be Energized / De-Energized

Output Relay Connector

Output

2 3 4 5 6

V1 +

V1 -

V2 +

V2 -

Connect 24 Volt supply to V1 +/- and V2

+/-. (See Connector diagram.)

Outputs 0-15 use common ground (V1 -)

Outputs 16-31 use common ground (V2

0.2 Amp per output max current Outputs 0-15 Max current 1.6A

Outputs 16-31 Max current 1.6A

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B.2 4 to 20mA Module (2 Points per Module) (PN: 2-500-011)

TR+

SLD

+24V

V1+

I1+

V2+

I2+

TR-

0V FG

AG1

AG2

Labeled connector on each 4 to 20ma Module.

4-20 ma Output Circuit Wiring.

Description

Module

Connection

Symbol

Point 1 4 to 20 ma

I1+

I+ 1

AG1

AG 1

Point 2 4 to 20 ma

I2+

I+ 1

AG2

AG 1

Point 3 4 to 20 ma

I3+

I+ 2

AG1

AG 2

Point 4 4 to 20 ma

I4+

I+ 2

AG2

AG 2

Point 5 4 to 20 ma

I1+

I+ 3

AG1

AG 3

Point 6 4 to 20 ma

I2+

I+ 3

AG2

AG 3

Point 7 4 to 20 ma

I3+

I+

AG1

AG 4

Point 8 4 to 20 ma

I4+

I+ 4

AG2

AG 4

Module

Address

Module 1

Module 2

Module 3

Module 4

IMPORTANT: Use only connections above shown in grey. Other connections are

pre-wired in the CL4/CL8.

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B.2.1 4 to 20mA Module (4 Points per Module) (PN: 2-500-011)

TR+

SLD

+24V

AG1

V2+

I2+

V3+

I3+

AG4

FG*

TR-

V1+

I1+

AG2

FG*

AG3

V4+

I4+

GND

Labeled connector on each 4 to 20ma Module. *Each ‘FG’ terminal may be used for 2 points.

4-20 ma Output Circuit Wiring.

Description

Module

Connection

Symbol

Point 1 4 to 20 ma

I1+

I+ 1

AG1

AG 1

FG*

Point 2 4 to 20 ma

I2+

I+ 1

AG2

AG 1

FG*

Point 3 4 to 20 ma

I3+

I+ 1

AG3

AG 1

FG*

Point 4 4 to 20 ma

I4+

I+ 1

AG4

AG 1

FG*

Point 5 4 to 20 ma

I1+

I+ 2

AG1

AG 2

FG*

Point 6 4 to 20 ma

I2+

I+ 2

AG2

AG 2

FG*

Point 7 4 to 20 ma

I3+

I+ 2

AG3

AG 2

FG*

Point 8 4 to 20 ma

I4+

I+

AG4

FG*

Module

Address

Module 1

Module 2

IMPORTANT: Use only connections above shown in grey. Other connections are

pre-wired in the CL4/CL8.

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B.3 8-Point Module (PN: 2-500-012)

TR+

SLD

+24V

V+

COM

TR-

V-

0 1 2 3 4 5 6

Labeled connector on each 8 Point Relay Module. See drawing below.

Module

Address

8 Point Relay

Module

IMPORTANT: Use only connections above shown in grey. Other connections are

pre-wired in the CL8.

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B.4 Optional Mechanical Relays

Description

Output

Point 1 Alarm Level 1

Point 1 Alarm Level 2

Point 2 Alarm Level 1

Point 2 Alarm Level 2

Point 3 Alarm Level 1

Point 3 Alarm Level 2

Point 4 Alarm Level 1

Point 4 Alarm Level 2

Point 5 Alarm Level 1

Point 5 Alarm Level 2

Point 6 Alarm Level 1

Point 6 Alarm Level 2

Point 7 Alarm Level 1

Point 7 Alarm Level 2

Point 8 Alarm Level 1

Point 8 Alarm Level 2

Critical Fault (Fault)

SPARE (UNUSED)

Power On

Analysis Mode (Out of Analysis)

General Fault (Maintenance)

Gas Alarm Level 1

Gas Alarm Level 2

NOTES

240 VAC max per relay Xx Amps max current per relay

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B.4.1 Optional Mechanical Relay Wiring

Below is a typical wiring diagram to connect a Form C Relay to any of the sinking outputs described in Appendix Section B.1 Note: You must connect 24V + to both V1+ / V2+ AND connect 24V- to both V1-/ V2on the connector as shown below.

Output

2 3 4 5 6 7 8 9 10

V1 +

V1 -

V2 +

V2 -

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24 V+

24 V -

N/O

COMM

N/C

COIL

Form C Relay

DOD Customer

24V Sinking

Output Module

(See Section

Attach to

desired

output 0-31

on connector

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B.5 OPC Interface (PN: 2-500-501)

Use the RJ-45 connector pictured below to connect the CL4/CL8 to the I/P:network when the optional OPC Interface (OPC I/F) is specified. The connector is located on the inside of the machine next to the top DINrail.

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Appendix C – System Specifications

Physical Dimensions

Height

20”

Width

20”

Depth

11.3”

Weight

Approx. 70 lbs.

Tubing

Exhaust Line (1)

3/8” OD x 5/16” ID Polypropylene (25 ft. max length)

Sample Lines (8)

1/ 4” OD x 3/16” ID Teflon FEP (300 ft. max length)

Power

A/C Power

(100-120 VAC, 50/60 HZ) ( 220/240 VAC, 50/60 HZ)

Standard Output Relays

Rated Output Voltage

DC 24V

Rated Output Voltage Range

DC 20.4V - 28.8V

Maximum Load Voltage

0.2A/Connection (1.6A maximum pts 0-15 & pts 16)

Output Protection

None

Transport

Transport Times

Approx. 36 Seconds at 250 ft. 18 seconds at 125 ft.

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Appendix D – System Event Messages

COLOR CODING

RED

Gas Alarm

ORANGE

Service Fault (critical)

YELLOW

Maintenance (non-critical)

BLUE

Information Message

GREEN

Status (during analysis)

Event Code

Message

Corrective Action

30000

System Communication Failure

Service required

30001

All Points Are Disabled

Enable 1 or more points - sections 4.2.a

30002

Low flow multiple points

Check pump, gate, or adjust flow

30003

Gate Close Fault

Gate home switch stuck or gate not moving

30004

Gate open Fault

Check gate home switch and/or mechanism

30005

High background Fault

Check/replace tape

30006

I/O Failure - Check wiring

Check RS-485 wiring

30007

No Gas Family Selected

Service required

30008

Pump failure

Check pump wiring/flow

30009

Tape Advance Fault

Tape switch not activated before timeout

30010

Optic 1 Communication Error

Check Wiring or Optic 1

30011

Optic 2 Communication Error

Check Wiring or Optic 2

30012

High Background Tape Advance Fault

Check/replace tape

30013

LED Failure Optic 1

Possible Tape alignment problem

30014

Warning : Default values restored

Reconfigure & Calibrate

30015

Pump Timeout Error

Pump failure or system problem

30016

Tape Advance Problem

Service required

30017

Optic 1 LED Failure

Service required

30018

Optic 2 LED Failure

Service required

30019

Optic Supply Voltage Failure

Service required

30020

Optic reference validation fault

Service required

30021

LED Failure Optic 2

Service required

30022

Complete Optic Low Flow all Pt 1-4

Check gate closure

30023

Complete Optic Low Flow all Pt 5-8

Check gate closure

30024

LED Calibration error

50000

Chemlogic tape supply low

Change Tape

50001

Pt X High Flow

Flow Adjustment - Section 4.2.d

50009

Pt X Low Flow

Flow Adjustment - Section 4.2.d

60000

8 Hour - conc. detected

60010

Last analysis - Conc. detected

60011

Alarms & Faults Reset

60012

Error Transferring TWA/Analysis Summary

60013

Flow Fluctuation

60014

Maximum # of Ref fluctuations

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60015

LED Fluctuation fault

60016

Temperature fluctuation - O1

60017

Temperature fluctuation - O2

60018

K Factor - all pts = 1.000

60019

K Factor - some pts <> 1.000

60020

Reference fluctuation point X

60028

Power UP Time

60029

PT X Disabled

60030

Tape Counter Reset

60031

Simulation Mode

60032

Simulation Enabled Point 1

70000

DIAGNOSTIC STATUS OK

70001

8 Hour - no conc. all points.

70002

Analysis Start Time

70003

Last analysis - no Conc. found

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Appendix E – Gas Specifications

Family

Gas

Range

LDL

Full Scale

Alarm Level 1 Default

Alarm Level 2 Default

Tape Part #

120 Day Ammonia

NH3

NH3(0-75)ppm

1.2

1-700-012

120 Day Hydrides

AsH3

AsH3(0-500)ppb

5.4

500

100

1-300-012

120 Day Hydrides

B2H6

B2H6(0-1000)ppb

6.0

1000

100

200

1-300-012

120 Day Hydrides

PH3

PH3(0-1500)ppb

4.9

1500

300

600

1-300-012

120 Day Hydrides

SiH4

SiH4(0-50)ppm

0.2

50 5 10

1-300-012

120 Day Hydrides

H2S

H2S(0-20)ppm

0.2

1-300-012

120 Day Hydrides

H2S

H2S(0-5)ppm

0.1 5 0.5 1 1-300-012

120 Day Hydrides

SiH4

SiH4(0-50)ppm

0.2

50 5 10

1-300-012

120 Day Phosgene

COCl2

COCl2(0-1000)ppb

8.9

1000

100

200

1-200-012

120 Day Phosgene

COCl2

COCl2(0-300)ppb

3.9

300

100

200

1-200-012

120 Day Phosgene

COCl2

COCl2(0-3250)ppb

8.8

3250

100

200

1-200-012

120 Day Phosgene

COCl2

COCl2(0-5000)ppb

8.8

5000

100

200

1-200-012

120 Mineral Acids

HCL

HCL(0-15)ppm

0.2

15 5 10

1-400-012

120 Mineral Acids

HF(0-10)ppm

0.2

10 3 6

1-400-012

120 Mineral Acids

BF3

BF3(0-3200)ppb

72.2

3200

1000

2000

1-400-012

120 Mineral Acids

HBR

HBR(0-20)ppm

0.2

20 3 6

1-400-012

60 Day Hydrides

AsH3

AsH3(0-500)ppb

4.7

500

100

1-300-010

60 Day Hydrides

B2H6

B2H6(0-1000)ppb

31.5

1000

100

200

1-300-010

60 Day Hydrides

PH3

PH3(0-1500)ppb

8.4

1500

300

600

1-300-010

60 Day Hydrides

SiH4

SiH4(0-50)ppm

0.7

50 5 10

1-300-010

60 Day Hydrides

H2S

H2S(0-25)ppm

0.1

1-300-010

60 Day Mineral Acids

HCL

HCL(0-15)ppm

0.2

15 5 10

1-400-010

60 Day Mineral Acids

HF(0-10)ppm

0.3

10 3 6

1-400-010

60 Day Mineral Acids

BF3

BF3(0-3200)ppb

72.1

3200

1000

2000

1-400-010

60 Day Mineral Acids

HBR

HBR(0-20)ppm

0.2

20 3 6

1-400-010

60 Day Phosgene

COCl2

COCl2(0-1000)ppb

8.9

1000

100

200

1-200-010

60 Day Phosgene

COCl2

COCl2(0-4000)ppb

8.9

4000

100

200

1-200-010

Acetic Acid

Acetic Acid(0-50) ppb

0.7

1-490-010

Bromine

Br2

Br2(0-1000)ppb

68.8

1000

100

200

1-490-062

Chlorine

CL2

CL2(0-2000)ppb

6.9

2000

500

1000

1-500-010

COS

COS(0-20)ppm

0.9

20 5 10

1-300-062

HCN

HCN(0-2500)ppb

298.2

2500

500

1000

1-800-010

Hydrazine

N2H4

N2H4(0-500)ppb

4.3

500 5 10

1-D11-010

Low Level Chlorine

CL2

CL2(0-30)ppb

1.0

30 5 10

1-500-014

Low Level Hydrides

H2Se

H2Se(0-500)ppb

5.1

500

100

1-300-012

Low Level Hydrides

AsH3

AsH3(0-50)ppb

0.9

50 5 10

1-300-012

Low Level Hydrides

GeH4

GeH4(0-2000)ppb

62.1

2000

200

400

1-300-012

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Low Level Hydrides

PH3

PH3(0-300)ppb

4.8

300

100

1-300-012

MIC

MIC(0-100)ppm

3.7

100

1-600-010

NO2

NO2(0-100)ppm

0.3

100 3 6

1-600-511

Oxidizers

CL2

CL2(0-3200)ppb

50.1

3200

500

1000

1-550-010

Oxidizers

NO2

NO2(0-30)ppm

1.3

30 3 6

1-550-010

Oxidizers

F2(0-3200)ppb

105.6

3200

1000

2000

1-550-010

Pyrolyzer - M/A

C5F8

C5F8(0-15)ppm

0.5

15 2 4

1-400-014

Pyrolyzer - M/A

NF3

NF3(0-15)ppm

0.5

15 2 4

1-400-014

Velcorin

DMDC

DMDC(0-200)ppb

8.8

200

1-200-030

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Appendix F – USB Memory Stick Data

To ensure that historical and performance information is stored properly be sure to insert a USB Memory Stick in the proper slot at all times. See section 6.6 for installation instructions.

The USB Memory Stick stores all information in standard comma separated values (*.CSV) format for easy access with any computer. Remove the USB Memory Stick from the CL4/CL8 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 could be viewed with any standard text editor.

Figure B.1 below shows the folders and files found on the USB Memory Stick depending on the configuration or your CL4/CL8 and the use of the USB Memory Stick.

Figure B.1

F.1 Alarm & Event files (ZG*.CSV)

A portion of a typical event file when viewed with a spreadsheet program is shown below. Since the messages are written in reverse chronological order the recovery time shown is above the time of occurrence of the message.

NOTE : The columns labeled ‘Acknowledge Time’, ‘No. of Occ’, and ‘Acc Time’

are for DOD use only.

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Trigger

Date

Trigger

Time

Message(s)

Acknowledge

Time

Recovery

Time

No. of

occ.

Acc. time

Level

11/7/2006

17:32:00

8 Hour - no conc. all

points.

0:14:17 7

8 Hour - no conc. all

points.

9:32:20

0:14:17

11/7/2006

9:32:00

8 Hour - no conc. all

points.

0:14:17 7

8 Hour - no conc. all

points.

1:32:21

0:14:17

11/7/2006

1:32:00

8 Hour - no conc. all

points.

0:14:17 7

8 Hour - no conc. all

points.

17:32:32