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ChemLogic® 1 & 2
Continuous Gas Monitor User Manual
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© DOD Technologies, INC
675 Industrial Drive Bldg. A.
Cary, IL 60013
Phone 815.788.5200 • Fax 815.788.5300
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EC DEC LAR AT ION OF CO NFO RM ITY
EU DEC LAR AT ION OF CO NF ORM 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: CL1/CL2
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
Chapter 2 – Features ..................................................................................................................................................................... 9
2.1 External Layout ..................................................................................................................................................................... 9
2.1.1 Warning Labels, Descriptions, & Danger Zones .............................................................................................................. 9
2.1.2 ChemLogic® 1 & 2 Danger Zones ................................................................................................................................... 10
2.1.3 Maintenance Door ........................................................................................................................................................... 10
2.1.4 Keypad & Display ............................................................................................................................................................. 11
2.1.5 ChemLogic® Tape and Take-up Reel ............................................................................................................................. 11
2.1.6 Gas Inlet & Exhaust .......................................................................................................................................................... 11
2.1.7 A/C Power & Switch ......................................................................................................................................................... 11
2.1.8 14-Pin I/O Connector ...................................................................................................................................................... 11
2.2 Maintenance Area ............................................................................................................................................................... 11
2.3 Internal Layout – Service Area .......................................................................................................................................... 12
2.4 Micro Secure Digital Card (SD Card) ................................................................................................................................. 12
Chapter 3 – Installation ............................................................................................................................................................... 13
3.1 Selecting A Location ........................................................................................................................................................... 13
3.1.1 Lifting Instructions .......................................................................................................................................................... 13
3.2 Mounting ............................................................................................................................................................................. 14
3.3 Sample Tubing .................................................................................................................................................................... 15
3.3.1 End of Line Particulate Filters ......................................................................................................................................... 15
3.4 Exhaust Tubing ................................................................................................................................................................... 15
3.5 A/C Power ............................................................................................................................................................................ 15
3.6 Output Wiring ...................................................................................................................................................................... 15
Chapter 4 – Setup & Configuration ............................................................................................................................................. 17
4.1 User Checklist ..................................................................................................................................................................... 17
Chapter 5 – Basic Operation ....................................................................................................................................................... 18
5.1 Using the Keypad ................................................................................................................................................................ 18
5.2 Alarm & Fault Screens ........................................................................................................................................................ 18
5.3 Menu Overview CL1/Cl2 ..................................................................................................................................................... 20
5.4 Power-on Initialization ....................................................................................................................................................... 20
5.5 Main Menu ........................................................................................................................................................................... 21
5.5.1 Start Analysis ................................................................................................................................................................... 21
5.5.2 System Faults .................................................................................................................................................................. 22
5.5.3 Gas Alarms ....................................................................................................................................................................... 22
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5.5.4 Gate & Tape ...................................................................................................................................................................... 23
5.5.5 Alarm Levels ..................................................................................................................................................................... 23
5.5.6 Event & Alarm History ...................................................................................................................................................... 23
5.5.7 Test Alarms ...................................................................................................................................................................... 23
5.6 Setup Menu ......................................................................................................................................................................... 24
5.6.1 Main Menu ....................................................................................................................................................................... 24
5.6.2 Tape Saver ....................................................................................................................................................................... 24
5.6.3 Latching Relays ............................................................................................................................................................... 25
5.6.4 Enable Pumps .................................................................................................................................................................. 26
5.6.5 Enable Points ................................................................................................................................................................... 26
5.6.6 Energized Alarm Relays................................................................................................................................................... 26
5.6.7 Idle Timeout ..................................................................................................................................................................... 26
5.6.8 Date and Time .................................................................................................................................................................. 27
5.6.9 Test 4-20mA .................................................................................................................................................................... 27
5.6.10 Select Gas ...................................................................................................................................................................... 27
5.6.11 Conc. Logging (Concentration Logging) ...................................................................................................................... 27
5.7 Service Menu ....................................................................................................................................................................... 28
5.7.1 Voltage Cal ....................................................................................................................................................................... 28
5.7.2 Optic Calibration .............................................................................................................................................................. 28
5.7.3 Passwords........................................................................................................................................................................ 28
5.7.4 Optic Config...................................................................................................................................................................... 28
5.7.5 Status ............................................................................................................................................................................... 28
5.7.6 Clear History..................................................................................................................................................................... 29
5.7.7 Configuration ................................................................................................................................................................... 29
Chapter 6 – Maintenance ............................................................................................................................................................ 30
6.1 Maintenance Door Access ................................................................................................................................................. 30
6.2 Service Door Access ........................................................................................................................................................... 30
6.3 ChemLogic® Paper Tape .................................................................................................................................................... 31
6.4 End-of-Line Particulate Filters .......................................................................................................................................... 33
6.5 Flow Adjustment ................................................................................................................................................................. 34
6.6 Micro Secure Digital (SD) Card Replacement ................................................................................................................... 34
6.7 Fuse Replacement .............................................................................................................................................................. 34
6.8 Grease Application.............................................................................................................................................................. 35
Chapter 7 – Service & Support .................................................................................................................................................... 36
Appendix A – Accessories & Spare Parts .................................................................................................................................. 37
Appendix B – I/O Connection Detail ........................................................................................................................................... 40
Appendix C – Technical Specifications...................................................................................................................................... 41
Appendix D – System Event Messages ...................................................................................................................................... 42
Appendix E – Gas Specifications ................................................................................................................................................ 45
Appendix F – Removable Media ................................................................................................................................................. 48
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F.1 Concentration Log Files ..................................................................................................................................................... 48
F.2 Event Log Files .................................................................................................................................................................... 48
F.3 Formatting Micro SD Disks ................................................................................................................................................ 49
F.3 SD Card Status Menu Item ................................................................................................................................................. 51
Appendix G – ChemLogic® Cassettes ........................................................................................................................................ 52
Appendix H – Advanced Optics Cleaning Procedure ................................................................................................................ 53
H.1 Optic Orifice Cleaning ........................................................................................................................................................ 55
Appendix I – Additional Options ................................................................................................................................................. 56
I.1 Pressure Check Disable Mode ............................................................................................................................................ 56
I.2 Optics Auto Calibration ....................................................................................................................................................... 56
I.3 Maintenance Relay .............................................................................................................................................................. 56
I.4 Z-Purge Enclosures with Vortex (A/C) Coolers ................................................................................................................. 57
I.5 New Light Option ................................................................................................................................................................. 59
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Chapter 1 – Overview
1.1 Introduction
WARNING:
Operation of the ChemLogic® 1 & 2 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: solutions@dodtec.com
The ChemLogic® 1 & 2 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® 1 & 2 continuously monitors a single or double location (called a point)
for toxic and corrosive gas. It responds to gas that exceeds 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/CL2 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/CL2 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 be leaking.
The CL1/CL2 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/CL2 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/CL2.
1.3 Flow Connections
Flow connections consist of “quick-connect” ports on the bottom and side of the CL1/CL2. There is one inlet
and one exhaust outlet.
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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/CL2
provides all electrical connections for the outputs and remote reset.
NOTE: Maximum Branch-Circuit Rating = 20 Amperes
1.5 Theory of Operation
The sample flow is diverted across the ChemLogic® Tape. The ChemLogic® 1 & 2 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 & 2. The ChemLogic® 1 & 2 will then report an appropriate gas concentration reading
and/or a gas alarm.
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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® 1 and 2 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.
14 pin
I/O Connector
A/C Power &
Switch
ChemLogic® Tape
Maintenance Door
Take-up reel
Exhaust Outlet
Keypad & Display
Gas tubing inlet
(underside)
Door latches
(side of unit)
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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® 1 & 2 Danger Zones
Please be aware of the following danger zones on the ChemLogic® 1 and 2 continuous gas detection
equipment. Each zone contains warning labels for operator safety. Label meanings/descriptions can
be found in the above table.
A
WARNING:
This danger zone is located on the right side of the unit. It is the
warning for electrical shock in the following danger zone C.
B
WARNING:
This danger zone is located on the gate assembly. During
operation, operators could pinch fingers if not aware of
hand placement.
C
WARNING:
This danger zone is in the interior of the unit after zone A.
Operators could experience electric shock here if caution is
not exercised.
2.1.3 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.
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IMPORTANT: The maintenance door should remain closed and latched except when changing the
ChemLogic® tape.
2.1.4 Keypad & Display
The CL1/CL2 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.
2.1.5 ChemLogic® Tape and Take-up Reel
ChemLogic® paper tapes are accessed by opening the maintenance door. Refer to chapter 6 regarding tape
installation/replacement.
2.1.6 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/CL2. 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.
IMPORTANT: End of line filters are required. See section 6.4.
2.1.7 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.
2.1.8 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/CL2. Figure 2.2 shows
the internal layout with the access panel open. See section 6.3 for tape installation.
Figure 2.2
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2.3 Internal Layout – Service Area
Internal access to the CL1/CL2 for service uses the latches located on the right side of the front panel. Figure
2.3 shows the internal layout of the CL1/CL2 with the service door open.
The door should be opened by trained service personnel (See section 6.2)
Figure 2.3
DANGER: Turn off the unit, disconnect A/C power and unplug the 14 pin I/O connector on the
side of the unit (if installed) before opening the service door.
2.4 Micro Secure Digital Card (SD Card)
The CL1/CL2 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.
Back of Service Door
Inside of Service Door
SD Card Access Door
Output Connection Block
Power Supply
Pumps
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Chapter 3 – Installation
3.1 Selecting A Location
The CL1/CL2 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 length.
• Using the shortest possible sample line length will reduce transport times and increase the response
time of the CL1/CL2.
• 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/CL2 requires stable temperature and humidity levels within range to operate properly (see
Appendix C)
NOTE: Options are available for heating or cooling the CL1/CL2 – Contact DOD Technologies for details.
RECOMMENDATIONS:
Do not place in a location which will expose the CL1/CL2 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:
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!
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Get as close to the load as possible
• Walk over to the load – don’t stand still and reach for it
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
3.2 Mounting
Refer to figure 3.1 for dimensional requirements for wall mount. Be sure the CL1/CL2 is properly secured to
the wall.
Figure 3.1
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3.3 Sample Tubing
Sample tubing connects to the CL1/CL2 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).
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.
IMPORTANT: Sample tubing used with the CL1/CL2 must be 1/4” OD x 1/8” ID FEP. Use of any other tubing
may damage the CL1/CL2 and/or cause inaccurate gas concentration readings.
3.3.1 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.
End of line particulate filters may be purchased from DOD technologies (see appendix A)
IMPORTANT: The CL1/CL2 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.
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/CL2. 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/CL2 to increase precision. When not in analysis the CL1/CL2
will output the 2ma calibrated value. There is a maximum of 500-ohm load impedance on the 4-20ma circuit.
See Appendix B for a listing of output module connections.
Gas Inlet on Bottom of CL1 / CL2
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DANGER: Turn off the unit, disconnect A/C power and unplug the 14 pin I/O connector on the
side of the unit (if installed) before any wiring modifications.
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Chapter 4 – Setup & Configuration
4.1 User Checklist
Follow this checklist to configure the CL1/CL2 for first time operation or after a software upgrade.
___ Set passwords (section 5.6.3)
___ Set system date and time (section 5.5.7)
___ Gas selection (section 5.5.9)
Appendix E contains the specifications for each gas.
___ Alarm level settings (section 5.4.5)
___ Latching relays (section 5.5.3)
___ Energized Relays (section 5.5.5)
___ Idle Timeout (section 5.5.6)
___ Testing Contacts (section 5.4.7)
___ Adjustment of 4-20 ma (section 5.5.8)
___ Install new ChemLogic tape (section 6.3)
___ Install removable media (section 6.6)
___ Format removable media (Appendix F.3)
___ Tape Saver Mode (TSM section 5.5.)
___ Grease the Gate Cam (section 6.7)
___ Verify Sample Inlet flow ( post software upgrade only )
Setup complete - Ready for monitoring.
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Chapter 5 – Basic Operation
5.1 Using the Keypad
The CL1/CL2 is controlled using the keypad located around the display. All the display screens are accessed
through a simple menu system.
NOTE 1) The arrow keys located under the screen are used for two purposes.
1. 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.
2. To select among multiple data fields on some of the screens for editing.
NOTE 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.
NOTE 3) When numeric entry is required on any screen the following procedure is used.
Use the arrow keys below the screen to select which field to edit. The currently selected box
will have a dashed line around it.
1 Press the <ENTER> key first
2 Use the numeric/function keys to enter the value
3 Also note the up arrow may be used for +/- and the down arrow may be used for the decimal point when
necessary.
4 Press the <ENTER> key again to complete the entry
NOTE: The <F1> key is used to exit analysis and return to the Main Menu.
5.2 Alarm & Fault Screens
Three types of messages used in the CL1/CL2:
Alarm messages (level 1 and level 2)
System faults (critical faults that terminate and/or prevent analysis)
Event messages (warnings, non-critical faults, and various events)
Note 2
Note 1
Note 3
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See Appendix D for a description of each message. The history log always keeps the most recent 128
messages of any type in memory. All three types of messages are also logged to the Micro SD card if
present.
Various screens are used in the CL1/CL2 to show some or all 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 like 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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5.3 Menu Overview CL1/Cl2
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 (Section 5.6.3)
5.4 Power-on Initialization
When the CL1/CL2 is powered on it will begin with an initialization screen (figure 5.4) which is followed by the
restart screen (figure 5.5).
If the operator touches the <MENU> soft key before the timer reaches 0 the Main Menu (section 5.5.1 )
appears otherwise after a timeout the system will automatically start analysis (section 5.4.1)
Figure 5.4
Figure 5.5
Start Analysis
System Faults
Gas Alarms
Gate & Tape
Alarm Levels
Fault/Alarm History
Test Alarms
Setup Menu
Service Menu
Main Menu
Voltage Cal
Optic Calib.
Passwords
Status
Optic Config
Clear History
Offsets
Configuration
Test 4-20ma
Main Menu (5.4)
Setup Mode
Auto Analysis
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
SD Card
Setup Menu (5.5)
See Note 1
Automatic
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5.5 Main Menu
Once the CL1/CL2 is configured the main menu contains all the screens necessary for normal operation. The
main menu is not password protected.
Figure 5.6
Each selection on the main menu is detailed below
5.5.1 Start Analysis
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.
Figure 5.7
The screen continuously displays the current gas concentration if the system remains in analysis mode.
WARNING – Tape Saver Mode may affect the display of actual gas concentration. See section 5.5.2 for a
complete explanation of Tape Saver Mode (TSM).
When the concentration exceeds one or both alarm level 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 5.4.3.
Tape Saver Mode indicator and timer (Section 5.4.2)
Current alarm levels
Gas concentration bar
graph shows % of full
scale
Press to display current
gas alarms
Press to display current
warnings and events
Indicates new warning or
event message(s)
Current gas concentration and units
Current gas being monitored, and
scale used
P1 or P2 flashing display when
pump disabled
Blinking “Full Scale” text
displayed when appropriate
When Tape Save Mode is NOT
active, displays # of days
remaining on ChemLogic® Tape.
Text blinks during alarm
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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 5.4.4
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 5.3.6).
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
5.3.6). Pressing <ESC> will return to the analysis screen.
5.5.2 System Faults
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
5.5.3 Gas Alarms
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
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5.5.4 Gate & Tape
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
5.5.5 Alarm Levels
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.
Figure 5.11
5.5.6 Event & Alarm History
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
5.5.7 Test Alarms
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 the faults are automatically reset.
Figure 5.13
Status
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5.6 Setup Menu
The Setup Menu contains the screens necessary to configure the CL1/CL2 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
5.6.1 Main Menu
Selecting this menu item will return to the main menu (Section 5.4)
5.6.2 Tape Saver
(Default Configuration: Disabled)
Tape Saver Mode is used to reduce tape advancement during a gas release. Three tape saver modes are
available on the CL1/CL2: Fixed Cycle mode
(Default)
, Single Reading, and Continuous. Use the upper left
soft key to select among the three modes.
DANGER: Make sure the Tape Saver Modes are completely understood before enabling. Tape Saver modes
allow the operator to bypass continuous gas monitoring.
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/CL2
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.
Use this soft key to select among 3 modes
# of minutes to wait before tape advance
Trigger Concentration
Current Mode
Use this soft key to toggle TSM ON
and OFF
Current state of Tape Save Mode
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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.
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.
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/CL2 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.
5.6.3 Latching Relays
(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).
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.
‘TSM’ displayed whenever Tape
Saver Mode is enabled. Blinking
‘TSM’ indicates TSM counter
running.
TSM seconds counter counts
down to 0 before tape advance.
During this time no analysis is
done.
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5.6.4 Enable Pumps
(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 5.4.2) Disabling both pumps will trigger a
critical system fault and prevent analysis mode.
Figure 5.18
5.6.5 Enable Points
(Only Available on CL2)
Like the Enable Pumps screen, this screen will allow either point on a CL2 to be enabled/disabled.
5.6.6 Energized Alarm Relays
(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
5.6.7 Idle Timeout
(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.
Figure 5.20
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5.6.8 Date and Time
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.
5.21
5.6.9 Test 4-20mA
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 420mA 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/CL2 and used in the 4-20mA scaling for gas
concentrations.
Figure 5.22
Figure 5.23
5.6.10 Select Gas
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
5.6.11 Conc. Logging (Concentration Logging)
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.
Figure 5.25
Figure 5.26
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5.7 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 5.6.3)
5.7.1 Voltage Cal
This menu item is for Factory or Service personnel use, under normal conditions this screen is not used. Hit
<Cancel> to return to the Service Menu.
5.7.2 Optic Calibration
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 5.27
5.7.3 Passwords
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 5.28
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.
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.
5.7.4 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.
5.7.5 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.
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5.7.6 Clear History
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 5.4.6) 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 figure 5.28
and <ESC> again to return to the Service menu.
Figure 5.29
WARNING – Clearing the history log is not recommended. There is no way to recover the entries after they
have been cleared.
5.7.7 Configuration
The configuration menu is for certified service personnel only.
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Chapter 6 – Maintenance
It is recommended for complete safety that the ChemLogic® 1 & 2 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.
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:
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/CL2 as shown in Figure 6.1. When
maintenance is complete be sure to close the maintenance door and secure the latch.
IMPORTANT: The maintenance door should always remain securely latched except when servicing the
ChemLogic tape or using the keys on the display
Figure 6.1
6.2 Service Door Access
DANGER: Service must be performed by trained personnel only. Turn off the unit, disconnect
A/C power and unplug the 14 pin I/O connector on the side of the unit (if installed) before
opening the Service Door.
Figure 6.2
Maintenance door
latch
Service door
Service door lock
(tool required)
Insert 3/32” Allen
wrench to remove
service door lock.
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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/CL2 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.
IMPORTANT: The service door must always remain securely latched with the safety lock installed when not
servicing the unit. Verify that both latches are secure, and the safety lock is installed to prevent unauthorized
access.
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.
IMPORTANT: Read Appendix G before handling ChemLogic® Cassettes.
ChemLogic Paper Tape Path
Figure 6.2
Review the paper tape path shown in figure 6.2
Open the maintenance door. (Section 6.1)
Select Gate & Tape from the main menu (Section 5.5.4)
Scroll down with the arrow keys and select “Gate & Tape”
Touch the <Open/Close Gate> soft key to open the gate.
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Remove the top tape sleeve with the tape spooled around it by gently pulling away
from the machine.
Remove the old tape reel from the bottom spindle by lifting over the washer.
Discard the old tape & cassette appropriately
Remove the new tape reel from the protective packaging.
Pull the sleeve off the new tape reel and place the reel on the bottom spindle.
Place the new sleeve on the top reel.
Feed the new tape through the system as shown in figure 6.2
Verify the tape position on all rollers before proceeding.
Fold the end of the tape and loop it through the spool bar.
Backside image of tape fold and insertion under the spool bar.
Turn the top spindle a full turn to secure the tape
Press the gate button several times to make sure the tape is advancing properly.
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On the screen touch the ‘Reset’ soft key. (See section 5.5.4)
WARNING: Keep fingers clear during tape advance.
6.4 End-of-Line Particulate Filters
End of line (point of detection) particulate filters which protect the CL1/CL2 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
Description
Suggested Replacement
DOD Filter Part No.
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
TDA
2, 4 Diaminotoluene
1 Month (Membrane)
OR
3 Month (Disposable filter)
60009 (Housing) + 600010 (Membrane)
OR
2-800-013
HCL
Hydrogen Chloride
1 Month (Membrane)
OR
3 Month (Disposable filter)
60009 (Housing) + 600010 (Membrane)
OR
2-800-013
HF
Hydrogen Fluoride
1 Month (Membrane)
OR
3 Month (Disposable filter)
60009 (Housing) + 600010 (Membrane)
OR
2-800-013
BF3
Boron Trifluoride
1 Month (Membrane)
OR
3 Month (Disposable filter)
60009 (Housing) + 600010 (Membrane)
OR
2-800-013
HBR
Hydrogen Bromide
1 Month (Membrane)
OR
3 Month (Disposable filter)
60009 (Housing) + 600010 (Membrane)
OR
2-800-013
COCL2
Phosgene
6 Months
780248
Diisocyanates
2 Months
2-600-217 (Housing) + 2-600-207
(Membrane)
Table 6.1
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6.5 Flow Adjustment
The pumps in the CL1/CL2 automatically adjust to keep a constant flow to the system. No manual
adjustment is necessary. Typical inlet flow rate should read between 700 – 1000 cc’s per minute.
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/CL2 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.
Figure 6.3
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/CL2 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/CL2 is powered is On or Off.
The CL1/CL2 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
NOTE: Micro SD disks formatted with the FAT32 file system will not work in the CL1/CL2. 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 3.15A Slow Blow 5X20MM fuse shown in figure 6.4.
Figure 6.4
Fuse
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6.8 Grease Application
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 to the rounded portion of the cam. – See Figures 6.5
below:
Figure 6.5
Top of gate mechanism
Bottom of gate mechanism
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Chapter 7 – Service & Support
For information on service and support for your CL1/CL2 contact DOD Technologies, INC. using the
information below.
Phone Support
M-F 8am – 5pm (Central Time Zone)
815.788.5200
Service Center
675 Industrial Drive Bldg. A.
Cary, IL 60014
United States
Visit our website
www.dodtec.com
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Appendix A – Accessories & Spare Parts
ChemLogic 2 Month Cassettes
1-200-020
Phosgene ChemLogic 60 Day Cassette
$128.00
1-300-020
Hydrides ChemLogic 60 Day Cassette
$128.00
1-300-022
Carbonyl Sulfide ChemLogic 60 Day Cassette
$128.00
1-400-020
Mineral Acids ChemLogic 60 Day Cassette
$128.00
1-490-020
Acetic Acid ChemLogic CL1 60 Day Tape
$165.00
1-500-020
Chlorine Oxidizer ChemLogic 60 Day Cassette
$128.00
1-500-024
Ultra-Low-Level Chlorine ChemLogic Tape 30 Day
$128.00
1-600-020
Diisocyanates ChemLogic 60 Day Cassette, (TDI / MDI / HDI / IPDI)
$128.00
1-600-022
Diisocyanate High Humidity ChemLogic 30 Day Tape
$128.00
1-600-040
Methyl Isocyanate ChemLogic 60 Day Tape
$128.00
1-700-020
Ammonia ChemLogic 60 Day Cassette
$128.00
1-700-040
TDA ChemLogic 60 Day Cassette
$128.00
1-800-020
Hydrogen Cyanide ChemLogic 30 Day cassette
$74.00
1-810-020
Sulfur Dioxide ChemLogic 30 Day Cassette
$74.00
1-D11-020
Hydrazine ChemLogic 60 Day Cassette
$128.00
1-E15-020
TDI & MDI SPXNO2 ChemLogic 60 Day Cassette
$140.00
1-E15-022
TDI & MDI SPXNO2 High Humidity ChemLogic 30 Day Tape
$140.00
Optional
14249
Tubing FEP 1/4 OD x 3/16 ID x 250' Continuous Length
$450.00
2-100-075
CL1 Secondary Enclosure with NEMA4X Vortex Cooler and Internal Heater
$4,900.00
2-200-024
Replacement CL1 HMI Controller for Units with Damaged Standard Screen
$864.00
2-600-223
CL1 Color HMI Controller Upgrade for Existing Units
$1,350.00
2-600-225
CL1 Color HMI Controller Upgrade for New Units
$900.00
2-200-201
Replacement CL1 HMI Color Controller for Units with Damaged Color Screen
$1,350.00
2-400-007
Tubing FEP 1/4 OD x 1/8 ID x 100'
$375.00
2-400-008
Tubing Exhaust Polyethylene 1/4 OD x 0.17 ID
$1.00/foot
2-500-500
Tubing FEP 1/4 OD x 3/16 ID x 1000'
$1,600.00
2-600-201
SPM conversion adaptive mounting kit
$120.00
2-600-202
SD Micro 1G, CF memory card
$70.00
2-600-203
Side Mounted Stack Light with Audible Alarm
$825.00
2-600-204
14 Pin Mating Connector for CL1
$75.00
2-600-205
Option CL1 Self-Cleaning Optics
$650.00
2-600-206
Option - CL1 Z Purge with form C contact closure for audible and visual
alarms (this option will bring the environment within the enclosure from Class
I/II Division 2 to Non-hazardous)
$2,500.00
2-600-208
Option - CL1 Carrying Handle
$200.00
2-600-209
Option CL1 Modbus TCP Interface
$425.00
2-600-210
Option CL1 Modbus RS485
$425.00
2-600-211
Option CL1 Maintenance Relay
$500.00
2-600-212
Option CL1 Viton Flow Upgrade
$200.00
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2-600-213
CL1 Light Extension Cable w/connectors - up to 100' - Specify Length
$180.00
2-600-214
Outdoor Rain Resistant End of Line Cone
$55.00
2-600-216
Option CL1 Split Sampling System
$350.00
2-600-218
Option CL1 Ethernet IP
$1,100.00
2-600-220
CL1 Explosion Safe (Zone 2) Light Tower Option Top Mount
$1,325.00
2-800-007
KIT Duct Mounting Adaptor for 1/4" Tubing
$32.00
2-800-008
KIT Duct Mounting Adaptor for 3/8" Tubing
$45.00
Replacement Filters
780248
Disposable non-corrosive end of line particulate filters
$11.00
(for Phosgene & Hydride units – 8 required)
60009
Filter Housing for use with Teflon membranes (each)
$85.00
(for Mineral Acid Units – 1 required)
60010
Teflon Membranes – 100 pieces – 47mm
$275.00
(for use with Part #60009)
2-100-A36
Assembly - CL1 Upper Fitting and Filter
$125.00
(replaces part number 2-100-A63)
2-500-502
Teflon Membranes – 10 pieces – 47mm
$50.00
(for use with Part #60009)
2-600-217
TDI Filter Dust Cone
$55.00
2-100-503
Filter H2S Scrubber
$155.00
2-600-207
Filter Media Disc for Dusty Diisocyanate Application
$65.00
(10/pack) (for use with Part #2-600-217)
2-800-013
Particulate Filter for use with Corrosive gases (recommended replacement
every 90 days or less)
$29.00
NOTE: All applications except Diisocyanates – 150’ Maximum Sample Length. Diisocyanates – 6” Maximum -
Sold in 100-foot increments
Spare Parts for CL1/CL2 Description
102531
Fuse 3.15A Slow Blow 5X20MM
$4.00
104213
Power Supply 5V, 12V, -12V
$89.00
60009
Assy Filter Housing for Corrosive Gases
$85.00
600010
Teflon Membranes for 60009 - 100Pk - 47mm
$275.00
780248
Particulate Filter
$11.00
870328
Pump CL1/SPM Standard
$295.00
1-400-001
Tubing 5/32 x 3.31 Black PVC (Transducer Tubing)
$1/ft.
2-100-040
CL1 Sample Manifold
$70.00
2-100-061
CL1 Service Door Lock
$45.00
2-100-A12
CL1 & CL8 Gate Open Assy with Cam
$596.00
2-100-A13
CL1 & CL8 Tape Advance Assy
$250.00
2-100-A18
CL1 Optics Back Plate with Sealing Foam
$83.00
2-100-A24
Assy CL1 Light w/Pole for Light Option w/6 Pin Connector
$675.00
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NOV 2018 815-788-5200
CL1 & CL2 Manual
2-100-A25
CL1 (ONLY) Optic Block Assembly
$820.00
2-100-A26
Assy Micro Switch Field Upgrade
$55.00
2-100-A27
Transducer Assembly w/ Wires
$50.00
2-100-A34
Assembly Tee Fitting with Double O-rings and with 2 Collets Removed
$12.00
2-100-A35
Assy CL1 Exhaust Fitting
$9.00
2-100-A36
Assembly - CL1 Upper Fittings & Filter Assy
$125.00
2-100-A64
Assy CL1 - Inlet Manifold - Rev B per ECR 46
$70.00
2-100-A69
CL1 Optic Block - Self Cleaning Option
$865.00
2-200-024
Replacement CL1 HMI Controller for Units with Damaged Standard Screen
$864.00
2-200-028
Switch Rocker SPST 15A Sealed
$35.00
2-200-030
Relay Form C 12VDC Coil
$14.00
2-200-201
Replacement CL1 HMI Color Controller for Units with Damaged Color Screen
$1,350.00
2-300-004
Gear 24 Teeth Take-Up
$45.00
2-300-008
Drive Belt 84 Links CL1
$35.00
2-300-009
Drive Belt 73 Links CL1
$35.00
2-400-006
FEP Tubing 2 mm ID x 4 mm OD (Tubing between optics out and upper fitting
manifold)
$6/ft.
2-600-202
Memory Card SD Micro 2G
$70.00
2-600-204
Option 14 Pin Mating Connector w/Strain
$75.00
2-600-207
Filter Media Disc for Dusty Diisocyanate Applications (10/pack)
$65.00
2-600-209
Option CL1 Modbus TCP Interface
$425.00
2-600-214
Outdoor Rain Resistant End of Line Cone
$55.00
2-600-217
CL1 Option Dust Cone for Diisocyanate Applications
$55.00
2-600-219
CL1 YZ PURGE OPTION WITH ATEX nP CERTIFIED for Zone 2 Group IIB+H2
$4,200.00
2-600-223
CL1 Upgrade to Color Touchscreen for Existing Units
$1,350.00
2-600-225
CL1 Upgrade to Color Touchscreen for New Units
$900.00
2-600-226
CL1 Remote Light Tower with Pole Mount
$925.00
2-100-039
Cam Wear Plate
$15.00
2-100-074
CL1 Optics Communication Cable
$22.00
2-100-A78
Tubing Assy CL1 Optics Exhaust
$10.00
2-100-A30
Assy CL1 CL8 Drive Roller w/Shaft
$72.00
2-400-003
Tubing FEP 5/32 X 3/32 Natural
$2.50/ft.
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NOV 2018 815-788-5200
CL1 & CL2 Manual
Appendix B – I/O Connection Detail
14-Pin Cl1/Cl2 I/O Connector
Figure B.1
Pin
Description
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 always energized 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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CL1 & CL2 Manual
Appendix C – Technical Specifications
Physical Dimensions
Height
12.5 “ (31.75 cm)
Width
10.25” (26.04 cm)
Depth
9” (22.86 cm))
Weight
30 lbs. (13.5 kg)
Operating Temperature
5 to 40 Degrees Celsius
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
Less than 1Amp 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)
Maximum Branch-Circuit Rating
20 Amperes
Misc.
Removable Media
Micro SD up to 2 GB formatted (FAT16 File System)
Noise Level
< 15 dB
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CL1 & CL2 Manual
Appendix D – System Event Messages
RED
Alarm
Gas Alarm
ORANGE
Fault
Service Fault
YELLOW
Fault
Minor Fault
BLUE
Event
Information Message
GREEN
Event
Status Update
CL1/C
L2
Msg
Code
Message
Possible Cause
Corrective Action
1
No Gas Data Loaded
System Restored
Contact DOD Technologies Support @ (815)
788-5200
2
DAC Calibration
Required
Optics Dirty
See manual appendix H for cleaning
instructions. Add filter to inlet if possible. Also,
re-adjust optics - make sure fresh tape is
inserted and gate is closed. Go to service
menu-Optic Calib and press start.
4
No Gas Selected
No Gas Selected
Select gas in setup menu-select gas option
5
Gate Open Fault
Motor did not leave
home
Make sure that all wires coming from the HMI
to the motor are fully inserted(Red (grey)=Q12
and black=0V). Verify belts are all connected
and cam is greased. If these steps do not
work, contact DOD Technologies Support @
(815) 788-5200
6
Gate Close Fault
Motor did not return
home
Check issue from "Gate and Tape" screen. If
the gate opens and does not stop, there is a
problem with micro switch. Make sure both
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
Technologies Support @ (815) 788-5200
7
High Background
Fault
No Tape Loaded
Go to "Gate & Tape" and load fresh tape.
Optics Dirty
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.
8
Optic Comm Failure
Electrical problem
Remove optic block cover and make sure all
wires going to the optics are fully inserted.
Contact DOD Technologies Support @ (815)
788-5200 if these steps do not correct the
problem.
9
All Pumps Disabled
Flow Blocked and/or
Unstable Inlet/Exhaust
When blockage is fixed, go to Setup Menu and
enable pumps. If problem persists, contact
DOD (815) 788-5200.
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CL1 & CL2 Manual
10
Flow Fluctuation
Fault
Flow Blocked and/or
Unstable Inlet/Exhaust
When blockage is fixed, go to Setup Menu and
enable pumps. If problem persists, contact
DOD (815) 788-5200.
11
Idle Timeout
Out of Analysis Beyond
Timer
Re-enter Analysis
12
Low Background
Fault
Wrong tape or optic
problem
Re-adjust optics - make sure fresh tape is
inserted and gate is closed. Then go to service
menu-Optic Calib and press start. If these
steps do not work, contact DOD DOD
Technologies Support @ (815)788-5200
13
Purge Option Fault
Tubing Blocked
Find block in sample line
14
Optic Auto Cal
Failure
Optics Dirty
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-Optic Calib and press start.
33
SD Card Fault
No SD Card or Card Full
If a SD card is installed remove and re-insert
34
Analyzing
Analysis mode started
N/A
35
ChemLogic Tape
Low
ChemLogic tape nearing
end
Replace tape
36
Pump 1 Disabled
Flow Blocked and/or
Unstable Inlet/Exhaust
Go to Setup Menu and enable pump. If
problem persists, contact DOD (815) 788-
5200.
37
Pump 2 Disabled
Flow Blocked and/or
Unstable Inlet/Exhaust
Go to Setup Menu and enable pump. If
problem persists, contact DOD (815) 788-
5200.
38
Large Flow
Fluctuation
Flow Blocked and/or
Unstable Inlet/Exhaust
When blockage is fixed, go to Setup Menu and
enable pumps. If problem persists, contact
DOD (815) 788-5200.
39
High Flow Fault
Optics Orifice Dirty
See manual appendix H for cleaning
instructions and add a filter to inlet if possible.
If problem persists, contact DOD (815) 788-
5200.
40
Alarm Level 1
Gas Detected
After gas leak is found and corrected, reset
alarms
41
Alarm Level 2
Gas Detected
After gas leak is found and corrected, reset
alarms
42
Remote Reset
N/A
43
Power On
N/A
44
Optic Calibration
Operator initiated
N/A
45
Pump 1 high voltage
Pump drawing high
current or Bad Pump
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.
46
Pump 2 high voltage
Pump drawing high
current or Bad Pump
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.
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CL1 & CL2 Manual
47
Warning : Optics
Dirty
Dirty Optics
See manual appendix H for cleaning
instructions and add a filter to inlet if possible.
If problem persists, contact DOD (815) 788-
5200.
48
Tape Saver Mode
Tape Saver Enabled
N/A
49
Hour Diagnostic OK
Hourly Checkup
N/A
50
Flow Failure 1 L
Optics Orifice Dirty
See manual appendix H for cleaning
instructions and add a filter to inlet if possible.
If problem persists, contact DOD (815) 788-
5200.
51
Flow Failure 2 L
Optics Orifice Dirty
See manual appendix H for cleaning
instructions and add a filter to inlet if possible.
If problem persists, contact DOD (815) 788-
5200.
52
Flow Disruption
Flow Inconsistent
Contact DOD Technologies Support @ (815)788-5200
53
Alarm Level 1 Pt 2
Gas Detected
After gas leak is found and corrected reset
alarms
54
Alarm Level 2 Pt 2
Gas Detected
After gas leak is found and corrected reset
alarms
55
Flow Failure 1 H
Sample Inlet Blocked or
Internal Leak
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.
56
Flow Failure 2 H
Sample Inlet Blocked or
Internal Leak
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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CL1 & CL2 Manual
Appendix E – Gas Specifications
ChemLogic
Cassette PN
Name
Gas
LDL
Full
Scale
Units
TLV
Alarm 1
Default
Alarm 2
Default
Response
Time TLV
(T100)*
seconds
1-700-020
Ammonia
NH3
1.2
75
ppm
25 ppm
25
50
12
1-400-020
Arsenic Pentafluoride^
AsF5 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-400-020
Arsenic Trichloride^^
AsHCl3 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-400-020
Arsenic Trifluoride^
AsF3 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-300-020
Arsine
AsH3
5.4
500
ppb
50 ppb
50
100
16
1-300-020
Arsine
AsH3
0.9
50
ppb
5 ppb
5
10
84
1-400-020
Boron Tribromide^^^
BBr3 (HBr)
0.2
20
ppm
3 ppm
3 6 12
1-400-020
Boron Trichloride^^
BCl3 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-400-020
Boron Trifluoride
BF3
72.2
3200
ppb
1000 ppb
1000
2000
12
1-400-020
Bromine
Br2
68.8
1000
ppb
100 ppb
100
200
20
1-300-022
Carbonyl Sulfide
COS
0.9
20
ppm
5 ppm
5
10
20
1-400-020
Carbonyl Fluoride^
COF2 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-600-020
Cyclohexane Diisocyanate
CHDI
2.4
100
ppb - 5
10
36
1-500-020
Chlorine
Cl2
44.6
5000
ppb
500 ppb
500
1000
20
1-500-020
Chlorine
Cl2
50.1
3200
ppb
500 ppb
500
1000
20
1-500-020
Chlorine
Cl2
6.9
2000
ppb
500 ppb
500
1000
20
1-500-024
Chlorine
Cl2 1 30
ppb
500 ppb
5
10
20
1-400-020
Chlorine Trifluoride^
ClF3 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-300-020
Diborane
B2H6
6
1000
ppb
100 ppb
100
200
12
1-400-020
Dichlorosilane^^
SiH3Cl2 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-550-020
Fluorine
F2
49.8
3200
ppb
1000 ppb
1000
2000
40
1-400-020
Fluorosilicic acid^
H2SiF6 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-300-020
Germane
GeH4
62.1
2000
ppb
200 ppb
200
400
180
1-400-020
Germanium Tetrafluoride^
GeF4 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-400-020
Hexachlorodisilane^^
SiCl2 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-600-020
Hexamethylene Diisocyanate
HDI
1.7
100
ppb
5 ppb
5
10
36
1-600-020
HMDI
HMDI
2.3
100
ppb - 5
10
24
1-D11-020
Hydrazine
N2H4
4.3
500
ppb
10 ppb
5
10
40
1-400-020
Hydrogen Chloride
HCl
0.2
15
ppm
5 ppm
5
10
12
1-400-020
Hydrogen Bromide
HBr
0.2
20
ppm
3 ppm
3 6 12
1-800-020
Hydrogen Cyanide
HCN
298.2
2500
ppb
20 ppb
500
1000
16
1-400-020
Hydrogen Fluoride
HF
0.3
10
ppm
2 ppm
2 4 12
1-300-020
Hydrogen Selenide
H2Se
5.1
500
ppb
50 ppb
50
100
20
1-300-020
Hydrogen Sulfide
H2S
13.3
1500
ppb
1000 ppb
100
200
20
1-300-020
Hydrogen Sulfide
H2S
13.3
500
ppb
1000 ppb
100
200
20
1-300-020
Hydrogen Sulfide
H2S
10
90
ppb
1000 ppb
100
200
20
1-300-020
Hydrogen Sulfide
H2S
0.2
50
ppm
1 ppm
10
20
20
1-300-020
Hydrogen Sulfide
H2S
0.2
20
ppm
1 ppm
1 2 20
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CL1 & CL2 Manual
1-300-020
Hydrogen Sulfide
H2S
0.1 5 ppm
1 ppm
1 2 20
1-600-020
Isophorone Diisocyanate
IPDI 1 100
ppb
5 ppb
5
10
24
1-600-020
Methylene Diphenyl Diisocyanate
MDI
1.7
200
ppb
5 ppb
5
10
80
1-600-020
Methylene Diphenyl Diisocyanate
MDI
1.7
100
ppb
5 ppb
5
10
80
1-600-022
Methylene Diphenyl Diisocyanate
MDI
1.7
100
ppb
5 ppb
5
10
80
1-E15-020
Methylene Diphenyl Diisocyanate
MDI
1.7
100
ppb
5 ppb
5
10
80
1-E15-022
Methylene Diphenyl Diisocyanate
MDI
1.7
100
ppb
5 ppb
5
10
80
1-600-020
Methylene Isocyanate
MIC
3.7
100
ppm
.02 ppm
2.5 5 24
1-600-020
Methylene Isocyanate
MIC
1.5
10
ppm
.02 ppm
2.5 5 24
1-400-020
Nitric Acid
HNO3
187.5
5000
ppb
2000 ppb
2000
4000
24
1-550-020
Nitrogen Dioxide
NO2
0.3
100
ppm
3 ppm
3 6 12
1-550-020
Nitrogen Dioxide
NO2
1.3
30
ppm
3 ppm
3 6 12
1-400-020
Phenyl Trichlorosilane^^
SiCl3Ph (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-200-020
Phosgene
COCl2
8.8
5000
ppb
100 ppb
100
200
12
1-200-020
Phosgene
COCl2
8.9
4000
ppb
100 ppb
100
200
12
1-200-020
Phosgene
COCl2
8.8
3250
ppb
100 ppb
100
200
12
1-200-020
Phosgene
COCl2
5.2
3000
ppb
100 ppb
100
200
12
1-200-020
Phosgene
COCl2
6.6
1000
ppb
100 ppb
100
200
12
1-200-020
Phosgene
COCl2
6.6
900
ppb
100 ppb
100
200
12
1-200-020
Phosgene
COCl2
3.9
300
ppb
100 ppb
100
200
12
1-300-020
Phosphine
PH3
4.8
300
ppb
300 ppb
50
100
16
1-300-020
Phosphine
PH3
4.9
1500
ppb
300 ppb
300
600
16
1-400-020
Phosphorus Oxychloride^^
POCl3 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-400-020
Phosphorus Pentachloride^^
PCl5 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-400-020
Phosphorus Pentafluoride^
PF5 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-400-020
Phosphorus Tribromide^^^
PBr3 (HBr)
0.2
20
ppm
3 ppm
3 6 12
1-400-020
Phosphorus Trichloride^^
PCl3 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-400-020
Phosphorus Trifluoride^
PF3 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-300-020
Silane
SiH4
0.2
50
ppm
5 ppm
5
10
16
1-400-020
Silicon Tetrachloride^^
SiCl4 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-300-020
Stibine
SbH3
14.6
500
ppb
100 ppb
100
200
16
1-810-020
Sulfur Dioxide
SO2
19.3
2500
ppb - 250
500
16
1-400-020
Sulfur Tetrafluoride^
SF4 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-400-020
Sulfuric Acid
H2SO4
26.2
750
ppb
50 ppb
50
100
20
1-400-020
Sulfuric Acid
H2SO4
97.1
3200
ppb
50 ppb
500
1000
20
1-400-020
Tetrafluorosilane^
SiF4 (HF)
0.3
10
ppm
2 ppm
2 4 12
1-400-020
Tin Tetrachloride^^
SnCl4 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-600-020
Toluene Diisocyanate
TDI
0.5
100
ppb
1 ppb
5
10
140
1-600-020
Toluene Diisocyanate
TDI 1 100
ppb
1 ppb
5
10
70
1-600-020
Toluene Diisocyanate
TDI 1 200
ppb
1 ppb
5
10
70
1-600-022
Toluene Diisocyanate
TDI 1 100
ppb
1 ppb
5
10
70
1-E15-020
Toluene Diisocyanate
TDI
0.5
100
ppb
1 ppb
5
10
300
1-E15-022
Toluene Diisocyanate
TDI
0.5
100
ppb
1 ppb
5
10
300
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CL1 & CL2 Manual
1-700-040
Toulene Diamine
TDA 4 60
ppb
10 ppb
10
20
12
1-400-020
Trichlorosilane^^
SiHCl3 (HCl)
0.2
15
ppm
5 ppm
5
10
12
1-400-020
Tungsten Hexafluoride^
WF6 (HF)
0.3
10
ppm
2 ppm
2 4 12
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CL1 & CL2 Manual
Appendix F – Removable Media
To ensure that historical and performance information is always stored properly be sure to insert a Micro Secure Digital (SD) card in the proper slot. 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/CL2 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/CL2 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/CL2, 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
F.2 Event Log Files
(YYMMDD*.CSV)
Each time a new event, fault or alarm is added to the History log on the CL1/CL2, 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.
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
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F.3 Formatting Micro SD Disks
The Micro SD Cards used in the CL1/CL2 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/CL2. The disks may be
formatted either from a PC or in the CL1/CL2.
It is highly recommended that the disk be formatted in the CL1/CL2 using the procedure outlined in the
following section instead of using a Windows based PC.
WARNING – Formatting the Micro SD card will erase all information stored on the card.
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. Formatting the disk in a MS Windows based PC
2. Insert the Micro SD card into the SD Card adapter included.
3. Insert the SD card adapter into the correct drive slot on the computer.
4. Open “My Computer”
5. 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.
6. Under the heading ‘File System’ select FAT – DO NOT SELECT FAT32
7. Uncheck the “Quick Format” box if it is selected
8. Press Start to format the disk.
When complete the disk is ready for use in the CL1/CL2.
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.
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Formatting the disk in the CL1/CL2
Figure 2.1
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 2.2
Use the down arrow key to scroll down until
you see the menu item “Removable Media”
as shown in figure 2.3
Figure 2.3
Press the <ENTER> key to select
“Removable Media” - this will display the
contents of the Micro SD card (screen may
look slightly different as shown in figure 2.4)
Figure 2.4
Press the softkey on the lower right side
which will bring up the screen shown in
figure 2.5
Figure 2.5
Press <F3> to format the disk which will
bring up the screen shown in figure 2.6.
Figure 2.6
Press the <ENTER> key to begin the format.
A Clock face pops up and minute hand
rotates till complete (several minutes).
When complete press <ESC> several times
to return the CL1/CL2 Main Menu.
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F.3 SD Card Status Menu Item
Whenever the concentration detected exceeds the preset alarm level in the CL1/CL2, 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
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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 always recommend that rubber gloves be worn while handling including removal and
installation.
Always wash hands as a precaution after handling DOD ChemLogic cassettes.
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Appendix H – Advanced Optics Cleaning Procedure
NOTE: Only perform this procedure when CL1 & CL2 display reads “DIRTY” or DAC value exceeds 150.
1. Enter the CL1 Main Menu
2. Enter the Service Menu (Password: 1234)
3. Enter “Optic Calib.”
4. Press “Open/Close”
5. Remove the ChemLogic
®
cassette tape from the gate
6. After the gate is open, remove the (2)
Phillips screws that hold the back-plane
block cover.
7. Remove the (2) Phillips screws holding the
back-plane block. The face of the optic
block should be exposed once completed.
8. You should see (4) circular holes with a
green light flashing in one channel at a time.
Each one of these holes represents a
channel. The CL1 only uses channel 2 for
gas detection
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9. To clean the fiber optic lenses, you will need
a Small cotton swab(Q-tip) and Industrial
alcohol.
10. Dip the cotton swab into the alcohol and
insert it in channel 2. It is very important to
clean both lenses. Make sure to put the
swab straight in to clean the first lens and
angled downward to clean the second lens.
11. After the cleaning is complete re-insert the tape and put the back-plane block on. Press
"Open/Close" and the gate will close.
12. Press start to initiate the calibration process. The current DAC value will become 0. Then the new
DAC value will populate. This new value should between 60-130 which is the manufacturers range.
DAC value cannot be improved from the value it is shipped at. Call DOD Technologies to check your
starting DAC value.
13. When done, the main menu should be on the display and press start analysis.
14. Once in analysis press F6 in order to see the technician screen.
15. In the technician screen you will see the
letter D. In front of the D is a number that
represents how bright your optic LED is.
When this number reaches 140 you will be
prompted to clean with a fault. When this
value reaches 150 your CL1 will not go in to
analysis until the optic block is cleaned.
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16. Repeat the cleaning process until this value is back to the manufacturer's DAC value range below
130.
17. Once the value is below 130 re-install the optic block covers.
H.1 Optic Orifice Cleaning
This procedure describes the cleaning of the CL1 / Cl2 optic orifice to prevent the buildup of debris around
the orifice that could cause increased pressure readings and decreased pump voltages.
1. Press F1 to exit analysis
2. Make sure the gate is closed
3. POWER OFF the CL1 / CL2 unit
4. Carefully remove the optic exhaust tube without pulling the optic wires loose
5. Spray compressed air into the optic exhaust channel down towards the inlet of the CL1 (You should
feel air coming out of the inlet)
6. Reinstall the optic exhaust tube
7. POWER ON the CL1 / CL2 unit
Figure H.1.1
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Appendix I – Additional Options
WARNING – These options should be changed only under direction from trained DOD service personnel.
Contact DOD for more information.
I.1 Pressure Check Disable Mode
(Default: OFF)
Useful for extreme conditions where the pressure at the sample point varies often. When enabled this option
will change the operation of the flow system in the CL1/CL2 as follows:
• Positive pressure into the system is ignored.
• Slight negative pressure will not cause flow fluctuation warnings.
• Flow fluctuation at the inlet is allowed if the negative pressure does not exceed the capability of the
pump to draw a valid sample pressure.
• ‘PRES’ is displayed on the screen during analysis when enabled. Note - ‘PRES’ displays only when an
SD card is inserted, the optics are clean, and the concentration is below full scale.
The flow into the system should be manually verified periodically when this mode is enabled
WARNING – Use caution when Pressure check disable mode is enabled as positive pressure may introduce
toxic gas into the system when the gate opens. In addition, displayed gas concentrations may not be
accurate when the flow level is not within normal limits of the CL1/CL2.
I.2 Optics Auto Calibration
(Default: ON)
When enabled the CL1/CL2 automatically adjusts the optics as needed during each tape advance and
displays a warning when the optics are dirty.
Disabling this option may cause HIGH BACKGROUND errors and require manual adjustment of the optics.
I.3 Maintenance Relay
(Option 2-600-211)
When option 2-600-211 is included the CL1/CL2 contains an extra relay which will trigger during three
maintenance fault conditions:
1. Tape Days Low Fault – Less than 3 days of ChemLogic tape remaining.
2. Optic Dirty Fault – The optics system needs to be cleaned.
3. SD Card Fault – The system cannot write to the SD storage card.
With this option there are 3 extra terminal blocks included inside the CL1/CL2 which are labeled “Q”,”R”, and
“S” as shown in figure I.3.1 below.
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Figure I.3.1
Terminal Q – Normally closed
Terminal R – Common
Terminal S – Normally open
** Also note that the relay is affected by the Energized/De-Energized setting in the CL1/CL2.
The maintenance relay has the same specifications as any of the relays available on the standard 14 pin
connector:
24 VDC 6 Amp Max – 240VAC 6 Amp Max
I.4 Z-Purge Enclosures with Vortex (A/C) Coolers
For your reference we have included the booklet for the Model YZ101 Purge Unit and the Operation & Safety
instructions for the Vortex cooler.
For more in-depth information you may reference NFPA 496 – Standard for Purged and Pressurized
Enclosures for Electrical Equipment.
Please follow the steps below to CONNECT THE PURGE SUPPLY TO THE CL1/CL2-purge enclosures.
WARNING: The Purge air (Instrument quality air or Inert Gas) intake MUST originate in a NON-HAZARDOUS
area.
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Please review (for reference) the “Protected Enclosure Criteria” and the
“Enclosure Connection Requirements” on pages 3 & 4 of the Model
YZ101 Operating Manual.
Refer to Model YZ101 Installation & Operating Manual for Unit Tubing
Instructions, requirements, and restrictions.
NOTE: the tubing size connection to the Unit Supply Connection has
been changed to 3/8”.
Refer to Operation & Safety Instructions for the Vortex Cooler for
Compressed Air Supply, Maintenance, Installation requirements, and
general information.
Vortex air inlet (3/8”) fitting.
For your reference we have included the booklet for the Model YZ101 Purge Unit. For more in-depth
information you may reference NFPA 496 – Standard for Purged and Pressurized Enclosures for Electrical
Equipment.
Please follow the steps below to set up and operate the CL1/CL2 z-purge enclosures.
BEFORE applying power to enclosure, Class I installations require four (4) volume exchanges through the
protected enclosure while maintaining a positive pressure. Follow this procedure each time before power is
switched on. If you have any questions contact DOD Technologies, INC before proceeding.
NOTE: The Purge supply should be of “Instrument Quality” air, free from any oils, dirt, and liquid(s). Inert gas
can substitute for “Instrument Quality” air as a Purge supply.
CAUTION: This procedure should only be used after the unit is properly installed and the supply of Purge air
(or inert gas) is connected properly to both the Vortex Cooler and the Purge Unit.
1. With Enclosure power off, remove any dust from enclosure (Class II applications).
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2. Confirm protected enclosure door(s) is sealed and Purge air supply is on.
3. Activate alarm system (if utilized), then adjust the Enclosure Pressure Control Regulator
unit until the Enclosure Pressure Gauge reads a minimum of 0.5” on the scale (Refer to
Figure below).
IF UNABLE TO REACH 0.5” ON GAUGE VERIFY THAT THE AIR SUPPLY IS ACTIVE, AND THE DOOR IS LATCHED
PROPERLY, THEN CHECK THE UNIT FOR LEAKS.
DO NOT PROCEED UNLESS A MINIMUM OF 0.5” IS READ ON THE SCALE WHILE THE VORTEX COOLER IS NOT
ACTIVE.
4. Next, turn the Enclosure Pressure Control Regulator 1 FULL turn clockwise and allow
Purge air to run for 2 Minutes (Minimum Purge Time) before continuing (Class I
applications).
CAUTION: Make sure the pressure remains in the SAFE range the entire time the unit is purging. It is
acceptable if Vortex cooler activates while unit is purging as long as needle remains above 0.5” in the SAFE
area on pressure gauge.
5. Once the required minimum time has elapsed AND the Enclosure Pressure reading is
still in the SAFE zone you may safely power on the unit.
WARNING: IMMEDIATELY remove power upon loss of SAFE pressure.
I.5 New Light Option
(Default: OFF)
Customers with the side panel mounted light option revision B or higher require CL1/CL2 software version
15.11 or higher and must enable this option in the Configuration menu for proper light operation. All previous
units without a revision label on the light option side panel or those with Revision A must have this option
disabled.
To enable/disable this option:
• From the main menu go to the Service Menu and enter the appropriate password
• From the Service Menu select Configuration and enter the appropriate key value – Contact DOD
service for assistance if needed.
• On the Configuration menu scroll down and select Options
• On the Options menu scroll and select “New Light Option”
• Change the value from 0 to 1 to enable the new light option.
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