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DOD Technologies ChemLogic 4 User Manual

Continuous gas monitor
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ChemLogic
4 & 8
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Continuous Gas Monitor User Manual

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  • Page 1 ChemLogic 4 & 8 ® Continuous Gas Monitor User Manual...
  • Page 2 CL4 & CL8 Manual © DOD Technologies, INC 675 Industrial Drive Bldg. A. Cary, IL 60013 Phone 815.788.5200 • Fax 815.788.5300 DC-ITD-CL4andCL8MAN01.A www.dodtec.com NOV 2018 815-788-5200...
  • Page 3 105 route des pommiers Centre Ubidoca 74370 St Martin Bellevue France DOD TECHNOLOGIES INC. declares under our sole responsibility that the product described as: Equipment Name: Continuous Gas Monitor Equipment Description: Detection and measurement of toxic gases Model: CL4/CL8 Serial number(s): _______________ Complies with the requirements of the following European Directives: Machinery Directive 2006/42/EC;...

  • Page 4: Table Of Contents

    Chapter 2 – Features ..................................9 2.1 External Layout ..................................9 2.1.1 Warning Labels, Descriptions, & Danger Zones ......................9 2.1.2 ChemLogic 4 & 8 Danger Zones ............................. 10 2.1.3 Status Lamp (OPTIONAL) ............................... 11 2.1.4 Output Wiring Knockouts ..............................11 2.1.5 Touch Screen Display..............................
  • Page 5 CL4 & CL8 Manual 3.6.1 Standard Output Relay Module Wiring ........................... 20 3.6.2 Optional 4 to 20ma Output Module Wiring ........................22 3.6.3 Optional 8 Point Relay Module (Item #2-500-012) ....................... 22 Chapter 4 - Setup & Configuration .............................. 23 4.1 Set system date and time ..............................
  • Page 6 CL4 & CL8 Manual 6.6 USB Memory Stick replacement ............................41 6.7 Apply grease periodically ..............................42 6.8 Fuse Replacement ................................42 Chapter 7 – Service & Support ..............................43 Appendix A – Accessories / Cassettes ............................44 Appendix B – I/O Connection Detail ............................46 B.1 Standard Output Relay Module ............................

  • Page 7: Chapter 1 - Overview

    Phone: +1 815-788-5200 email: solutions@dodtec.com The ChemLogic 4 (CL4) & 8 (CL8) continuous gas detection systems should be used exclusively for the quick detection of toxic, corrosive, and asphyxiant gases for process measurement and personnel safety purposes. Failure to comply with the intended purpose of the device may result in injury or death.

  • Page 8: Electrical Connections

    This color change results in a loss of reflected light across the ChemLogic tape. This loss of reflected light is detected by the advanced optics system in the ChemLogic 4/8. The ChemLogic 4/8 will then report an appropriate gas concentration reading and/or a gas alarm.

  • Page 9: Chapter 2 - Features

    2.1.1 Warning Labels, Descriptions, & Danger Zones The below table references all warning labels and their meanings that may be encountered while operating and servicing the ChemLogic 4 and 8 continuous gas detection equipment. WARNING: Hot Surface. This surface will be hot to touch and may cause injury. Please avoid or take caution when working near this zone.

  • Page 10: Chemlogic 4 & 8 Danger Zones

    2.1.2 ChemLogic 4 & 8 Danger Zones Please be aware of the following danger zones on the ChemLogic 4 and 8 continuous gas detection equipment. Each zone contains warning labels for operator safety. Label meanings/descriptions can be found in the above table This danger zone is in the service access point of the unit.

  • Page 11: Status Lamp (Optional)

    CL4 & CL8 Manual 2.1.3 Status Lamp (OPTIONAL) The optional status lamp consists of 4 colored lights – Red, Orange, Blue, and Green along with an audible alarm. See Appendix A for ordering information. 2.1.4 Output Wiring Knockouts There are two knockouts available for output wiring located on the top panel near the right side and on the right-side panel near the top.

  • Page 12: Take-Up Reel

    CL4 & CL8 Manual 2.1.11 Take-up reel An empty take-up reel is inserted at the time of ChemLogic tape installation (see section 6.3). During installation the previous take-up reel which is full is removed from CL4/CL8 and discarded. The previous ChemLogic tape reel which is now empty should then be used as the next take-up reel.

  • Page 13: Password Security

    CL4 & CL8 Manual DANGER: Turn off the unit and disconnect unplug A/C power to the unit before opening the Service Door. The door should be opened by trained service personnel (See section 6.2 ) USB Memory Stick Access (OPTIONAL) 4-20ma Output Connection output Block...

  • Page 14: Usb Memory Stick

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

  • Page 15: Chapter 3 - Installation

    CL4 & CL8 Manual Chapter 3 – Installation 3.1 Selecting a location The CL4/CL8 should be placed in a location as central as possible to the locations being monitored while considering the following restrictions: • The maximum sample line length is 300 ft. Using the shortest possible sample line length will reduce transport times and increase the response time of the CL4/CL8.
  • Page 16 CL4 & CL8 Manual 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 •...

  • Page 17: Mounting

    CL4 & CL8 Manual 3.2 Mounting Front Figure 3.1 DC-ITD-CL4andCL8MAN01.A www.dodtec.com NOV 2018 815-788-5200...
  • Page 18 CL4 & CL8 Manual Right Side Figure 3.2 Figure 3.4 DC-ITD-CL4andCL8MAN01.A www.dodtec.com NOV 2018 815-788-5200...

  • Page 19: Sample Tubing

    Replace the cover plate over the unused opening and secure with the four lock nuts. Figure 3.5 Sample tubing may be purchased from DOD technologies (see appendix A) IMPORTANT: All sample tubing used with the CL4/CL8 must be 1/4”OD x 3/16”...

  • Page 20: Exhaust Tubing

    CL4/CL8. Dust that collects in the tubing or the internal system may cause sample loss and inaccurate gas concentration readings. End of line particulate filters may be purchased from DOD technologies (see appendix A) 3.4 Exhaust tubing The exhaust line must be 3/8”...
  • Page 21 CL4 & CL8 Manual Figure 3.6 V1 + V2 + LOAD OUT 0 LOAD OUT 16 … … LOAD OUT 15 OUT 31 LOAD V1 - V2 - + 24V - + 24V - Figure 3.7 DANGER: Before performing any wiring modifications, be sure that power to the CL4/CL8 is disconnected and remove the output connector from the output relay block.

  • Page 22: Optional 4 To 20Ma Output Module Wiring

    CL4 & CL8 Manual 3.6.2 Optional 4 to 20ma Output Module Wiring Figure 3.8 details a typical connection to one of the eight (8) 4 to20ma output connections. See Appendix B for a complete list of terminal connections on the optional 4 to 20ma output block. Figure 3.8 DANGER: Before doing any wiring, modifications be sure that power to the CL4/CL8 is disconnected.

  • Page 23: Chapter 4 - Setup & Configuration

    CL4 & CL8 Manual Chapter 4 - Setup & Configuration 4.1 Set system date and time See section 5.2.2 4.2 Gas Selection Each point on the CL4/CL8 must be setup for the appropriate gas and configured accordingly. See section 5.2.1 for information on selecting the gas for each point. 4.3 Alarm Settings See section 5.2.a for information on how to adjust the alarm settings after the gas has been selected for each point.

  • Page 24: Usb Memory Stick

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

  • Page 25: Chapter 5 - Basic Operation

    CL4 & CL8 Manual Chapter 5 – Basic Operation CL4/CL8 Menu Overview I. Initialization (Power on) (sec. 5.1) Legend a. Setup Mode b. Timer User Screens II. Setup (11 button menu) (sec. 5.2) (No Password Required) a. Gas & Alarm Settings i.

  • Page 26: Setup / Main Menu

    CL4 & CL8 Manual Figure 5.2 Figure 5.3 If the operator touches the ‘SETUP MODE’ button before the timer reaches 0 the Setup screen appears (section 5.2) otherwise after a timeout the system will start analysis (section 5.4) 5.2 Setup / Main Menu The setup menu is accessed either by touching the ‘SETUP MODE’...

  • Page 27: Gas & Alarm Settings Menu

    CL4 & CL8 Manual 5.2.1 Gas & Alarm Settings Menu Touching the ‘GAS & ALARM SETTINGS’ button on the setup screen brings up the screen shown on the left in figure 5.5 which displays the configuration of points 1-5. Touching the ‘NEXT’ button will bring up the screen shown on the right of figure 5.5 which displays the configuration of points 5-8.

  • Page 28: Load Tape

    CL4 & CL8 Manual Figure 5.6 Touching any of the numeric displays for Month, Day, Year, and Time will bring up the numeric entry keypad. The time must be entered in 24-hour (Military) time format. Touch the ‘BACK’ button to return to the setup menu.

  • Page 29: Flow Adjustment

    CL4 & CL8 Manual Each time the ‘OPEN/CLOSE GATE’ button is touched, the gate will open or close appropriately. If the gate is currently closed, touching the button will open the gate. If the gate is currently open* touching the button will close the gate.

  • Page 30: Calibration Factors

    CL4 & CL8 Manual *NOTE: There may be a slight delay between the time the knob is turned, and the updated reading is reflected on the screen. Adjust the knob slowly and wait a few seconds to verify that the level is accurate. Adjust flow to this level.

  • Page 31: Set & Test Outputs

    CL4 & CL8 Manual Touching any of the numeric displays for any of the channels will bring up the numeric entry keypad. The value entered must be between 0.5 and 2.000 for each channel. NOTE: This screen requires the Administrator password for access – See section 5.2.6 Set &...

  • Page 32: Factory Settings

    CL4 & CL8 Manual 5.2.7 Factory Settings This button is reserved for technical service and requires a service password. Contact DOD Technologies, INC (section 7) for service information. 5.2.8 Event History Touching the ‘EVENT HISTORY’ button on the setup screen brings up the screen shown in figure 5.11.

  • Page 33: Concentration Log

    CL4 & CL8 Manual 5.3 Concentration Log Touching the ‘CONC LOG’ button on the Event History screen (section 5.2.9) will bring up the screen shown in figure 5.13. Page Up Up 1 message Go to last message Down 1 message Page Down Current See section 5.6...

  • Page 34: Analysis Mode

    CL4 & CL8 Manual In addition, the logging interval can be adjusted from the default of 2 seconds to a maximum of 10 minutes (600 seconds). 5.4 Analysis Mode Figures 5.13 shows the main analysis screen which is entered either automatically during power on or by touching the ‘START ANALYSIS’...

  • Page 35: Point Detail Screen

    CL4 & CL8 Manual At the bottom of the analysis screen on the right side is the current date & time and a message box below it. The message box will either display the blinking message ‘NO USB Memory Stick or will be blank if a USB Memory Stick is inserted in the machine.

  • Page 36: Time Weighted Average (Twa)

    CL4 & CL8 Manual Arrow keys to scroll through list of items List of items in current folder w/current selection highlighted. Use these Delete selected keys to item navigate when viewing a Touch ‘DISP’ to file. display contents of selected folder or file.
  • Page 37 CL4 & CL8 Manual The first screen displays the current TWA information including the minutes and seconds elapsed since the cycle started. The CL4/CL8 retains the most recent 5 analysis cycles (up to 40 hours) in addition to the current cycle in memory. The previous cycles are accessed by touching the ‘View History’ button which brings up the screen shown in the lower right of figure 5.17.

  • Page 38: Chapter 6 - Maintenance

    CL4 & CL8 Manual Chapter 6 – Maintenance It is recommended for complete safety that the ChemLogic 4/8 continuous gas detection system be serviced on-site every 6 months by a certified DOD Service Engineer or by submitting the unit to the manufacturer for routine maintenance.

  • Page 39: Chemlogic Paper Tape Installation Procedure

    CL4 & CL8 Manual ChemLogic Paper Tape Installation Procedure A. From the setup menu touch the ‘Load Tape’ button (section 5.2.3) B. Open the maintenance door. (Section 6.1) C. On the screen touch the ‘OPEN/CLOSE GATE’ button to open the gate D.

  • Page 40: End Of Line Particulate Filters

    CL4 & CL8 Manual 6.4 End of line particulate filters End of line (point of detection) particulate filters which protect the CL4/CL8 from damage are required on all 4/8 points including points not being monitored. Table 6.1 details the type of filter required for each gas – see also figure 6.2.

  • Page 41: Flow Adjustment

    CL4 & CL8 Manual Mineral Acids Filter Hydrides & Phosgene Filter Mineral Acids Disposable Filter Part Numbers: Part Number: Part Number Blue Housing: 60009 780248 2-800-013 Filter Membrane: 60010 Figure 6.2 6.5 Flow adjustment Each channel should be adjusted whenever a new ChemLogic tape or particulate filter is installed. See section 5.2.4 6.6 USB Memory Stick replacement It is highly recommended to keep a USB Memory Stick inserted in the unit at all times.

  • Page 42: Apply Grease Periodically

    CL4 & CL8 Manual a) Push the USB Memory Stick straight up ensuring the USB Memory Stick and slot are aligned properly. DO NOT REMOVE Figure 6.3 Section 5.5 describes viewing the files stored on the USB Memory Stick on the touch screen. Appendix F details the data stored on the USB Memory Stick and how to access it on a personal computer.

  • Page 43: Chapter 7 - Service & Support

    Please contact DOD Technologies for the safe return of your equipment. All discontinued units will be accepted back by DOD Technologies so proper recycling may take place. For information on how to return the unit contact us using the below information: Phone Support M-F 8:30am –...

  • Page 44: Appendix A - Accessories / Cassettes

    CL4 & CL8 Manual Appendix A – Accessories / Cassettes DC-ITD-CL4andCL8MAN01.A www.dodtec.com NOV 2018 815-788-5200...
  • Page 45 CL4 & CL8 Manual DC-ITD-CL4andCL8MAN01.A www.dodtec.com NOV 2018 815-788-5200...

  • Page 46: Appendix B - I/O Connection Detail

    CL4 & CL8 Manual Appendix B – I/O Connection Detail B.1 Standard Output Relay Module Output Relay Connector Description Output Point 1 Alarm Level 1 Point 1 Alarm Level 2 Point 2 Alarm Level 1 Point 2 Alarm Level 2 Point 3 Alarm Level 1 Point 3 Alarm Level 2 Point 4 Alarm Level 1...

  • Page 47: To 20Ma Module (2 Points Per Module) (Pn: 2-500-011)

    CL4 & CL8 Manual 4 to 20mA Module (2 Points per Module) (PN: 2-500-011) +24V Labeled connector on each 4 to 20ma Module. IMPORTANT: Use only connections above shown in grey. Other connections are pre-wired in the CL4/CL8. 4-20 ma Output Circuit Wiring. Module Address Description...

  • Page 48: To 20Ma Module (4 Points Per Module) (Pn: 2-500-011)

    CL4 & CL8 Manual B.2.1 4 to 20mA Module (4 Points per Module) (PN: 2-500-011) +24V Labeled connector on each 4 to 20ma Module. *Each ‘FG’ terminal may be used for 2 points. IMPORTANT: Use only connections above shown in grey. Other connections are pre-wired in the CL4/CL8.

  • Page 49: 8-Point Module (Pn: 2-500-012)

    CL4 & CL8 Manual B.3 8-Point Module (PN: 2-500-012) +24V Labeled connector on each 8 Point Relay Module. See drawing below. IMPORTANT: Use only connections above shown in grey. Other connections are pre-wired in the CL8. Module Address 8 Point Relay Module DC-ITD-CL4andCL8MAN01.A www.dodtec.com...

  • Page 50: Optional Mechanical Relays

    CL4 & CL8 Manual B.4 Optional Mechanical Relays Description Output Point 1 Alarm Level 1 Point 1 Alarm Level 2 Point 2 Alarm Level 1 Point 2 Alarm Level 2 Point 3 Alarm Level 1 Point 3 Alarm Level 2 Point 4 Alarm Level 1 Point 4 Alarm Level 2 Point 5 Alarm Level 1...

  • Page 51: Optional Mechanical Relay Wiring

    CL4 & CL8 Manual B.4.1 Optional Mechanical Relay Wiring Below is a typical wiring diagram to connect a Form C Relay to any of the sinking outputs described in Appendix Section B.1 Note: You must connect 24V + to both V1+ / V2+ AND connect 24V- to both V1-/ V2- on the connector as shown below.
  • Page 52 CL4 & CL8 Manual DOD Customer 24V Sinking Output Module (See Section B.1) 24 V - 24 V+ COIL COMM Attach to desired output 0-31 on connector Form C Relay DC-ITD-CL4andCL8MAN01.A www.dodtec.com NOV 2018 815-788-5200...

  • Page 53: Opc Interface (Pn: 2-500-501)

    CL4 & CL8 Manual B.5 OPC Interface (PN: 2-500-501) Use the RJ-45 connector pictured below to connect the CL4/CL8 to the I/P:network when the optional OPC Interface (OPC I/F) is specified. The connector is located on the inside of the machine next to the top DIN- rail.

  • Page 54: Appendix C - System Specifications

    CL4 & CL8 Manual Appendix C – System Specifications Physical Dimensions Height 20” Width 20” Depth 11.3” Weight Approx. 70 lbs. Tubing 3/8” OD x 5/16” ID Polypropylene Exhaust Line (1) (25 ft. max length) 1/ 4” OD x 3/16” ID Teflon FEP Sample Lines (8) (300 ft.

  • Page 55: Appendix D - System Event Messages

    CL4 & CL8 Manual Appendix D – System Event Messages COLOR CODING Gas Alarm ORANGE Service Fault (critical) YELLOW Maintenance (non-critical) BLUE Information Message GREEN Status (during analysis) Event Code Message Corrective Action 30000 System Communication Failure Service required 30001 All Points Are Disabled Enable 1 or more points - sections 4.2.a 30002...
  • Page 56 CL4 & CL8 Manual 60015 LED Fluctuation fault 60016 Temperature fluctuation - O1 60017 Temperature fluctuation - O2 60018 K Factor - all pts = 1.000 60019 K Factor - some pts <> 1.000 60020 Reference fluctuation point X 60028 Power UP Time 60029 PT X Disabled...

  • Page 57: Appendix E - Gas Specifications

    CL4 & CL8 Manual Appendix E – Gas Specifications Alarm Alarm Full Family Range Level 1 Level 2 Tape Part # Scale Default Default 120 Day Ammonia NH3(0-75)ppm 1-700-012 120 Day Hydrides AsH3 AsH3(0-500)ppb 1-300-012 120 Day Hydrides B2H6 B2H6(0-1000)ppb 1000 1-300-012 120 Day Hydrides...
  • Page 58 CL4 & CL8 Manual Low Level Hydrides PH3(0-300)ppb 1-300-012 MIC(0-100)ppm 1-600-010 NO2(0-100)ppm 1-600-511 Oxidizers CL2(0-3200)ppb 50.1 3200 1000 1-550-010 Oxidizers NO2(0-30)ppm 1-550-010 Oxidizers F2(0-3200)ppb 105.6 3200 1000 2000 1-550-010 Pyrolyzer - M/A C5F8 C5F8(0-15)ppm 1-400-014 Pyrolyzer - M/A NF3(0-15)ppm 1-400-014 Velcorin DMDC DMDC(0-200)ppb...

  • Page 59: Appendix F - Usb Memory Stick Data

    CL4 & CL8 Manual Appendix F – USB Memory Stick Data To ensure that historical and performance information is stored properly be sure to insert a USB Memory Stick in the proper slot at all times. See section 6.6 for installation instructions. The USB Memory Stick stores all information in standard comma separated values (*.CSV) format for easy access with any computer.

  • Page 60: Twa Data Logs (Tyymmdd.csv)

    The time weighted average information is stored on the USB Memory Stick in the TWA folder. A new file is started each day (named with the year, month, and day) for easy retrieval. Below is a sample of one cycle stored in a file. DOD Technologies INC http://www.dodtec.com Analysis Cycle...

  • Page 61: Config File

    12:19:48 AM F.4 Config File A configuration file is created on the USB Memory Stick each time the ChemLogic 4/8 is powered on. The config file stores basic information about the machine including version information, serial number, customer name (if entered), etc. All of the information is stored in CSV format for easy viewing.

  • Page 62: Appendix G - Chemlogic Cassettes

    CL4 & CL8 Manual 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.

  • Page 63: Appendix H - Optic Block Cleaning Procedure

    CL4 & CL8 Manual Appendix H – Optic Block Cleaning Procedure The CL4/CL8 may require periodic cleaning of the optics block when the instrument is used in environments with a high level of airborne particulate or a “High Background” Fault has been reported.

  • Page 64: Advanced Optics Cleaning

    CL4 & CL8 Manual Figure 4 Figure 5 9) Enter 1225 for the password then press “Enter”. 10) You should see the calibrate optics screen (Figure 5), then make sure the gate is closed and press “Calibrate”. 11) If the DAC values are 140 or below you are done. Go to “Main Menu” and clear the original faults and re-enter analysis.

This manual is also suitable for:

Chemlogic 8

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