DOD CL96 Technical & Service Manual
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DOD CL96 Technical & Service Manual

Gas detection system
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CL96 Gas Detection System
Technical Service Manual
Revision 16.11
DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300
DC-ITD-CL96Servicemanual
www.dodtec.com
Innovative Life Safety Systems & Services

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Summary of Contents for DOD CL96

  • Page 1 CL96 Gas Detection System Technical Service Manual Revision 16.11 DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-ITD-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...

  • Page 2: Table Of Contents

    Flow Path Verification Procedure: ....................30 I/O Verification Procedure: ....................... 31 Hardware Replacement: ........................... 34 DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-ITD-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...
  • Page 3 Appendix A: Control Wiring ........................39 Appendix B: Pump Panel Wiring ......................40 Appendix C: Analyzer Wiring ......................... 41 DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-ITD-CL96Servicemanual www.dodtec.com...

  • Page 4: Preventative Maintenance

    4. Select the System tab 5. Press the DAC button for any active analyzer (see image below ) DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 5: Background Verification

    4. Select the System tab 5. Press the ADC button for any active analyzer (see image below) DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 6: Flow System

    If there is an offset voltage outside of the suggested range remove the sample line and press Set Offsets. If the offset is still outside the suggested range refer to the CL96 Flow Troubleshooting Section. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 7: System Flow Balance

    5. Locate the Point Arrangement Label on the top of the Cl96 enclosure near the inlet manifold. 6. Use the black knobs to adjust and balance inlet flow on each point. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 8: Point Flow Check With Flowmeter

    Now locate the exhaust port for the related pump on the side of the CL96 (see image below) and plug it. When the exhaust port is plugged, all points should drop to the bottom of the scale in the yellow region. If the onscreen flowmeter does not drop to the bottom of the scale remove the CL96 rear panel and check for leaks between the exhaust port on the side of the cabinet and the exhaust port on the related pump.

  • Page 9: Tape Advance System

    3. Mark the tape after the optic blocks on the left hand side. (See picture below) 4. Advance the tape by pressing Open Gate then Close Gate DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 10: Micro Switch Verification

    DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 11: Lubricating Gate Assembly

    The CL96 comes with two 24VDC power supplies, one 12VDC power supply and one 5VDC power supply. Use the chart and images below to verify the voltages are within factory specifications. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 12 5VDC for the flow system can be measured at the red terminal block. The DC voltage verification should be done at the yellow terminal blocks mounted on DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 13 Because the pins are located next to each other this test should be done carfully to avoid a short and blowing a fuse DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 14: Vibration Damage And Wire Inspection

    The terminal block jumpers are located in the control box and on the pump panel on all of the terminal blocks. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 15: Faults & Troubleshooting

    3. Power cycle the CL96 DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...
  • Page 16 2. If not put the CL96 back into analysis DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...
  • Page 17 The PC cannot communicate with the 96144 Custom Output Module Failure Verification I/O modules Procedure. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...
  • Page 18 None needed 96155 Restarting PLC Connection Restarting PLC Connection None needed DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...

  • Page 19: Optic Cleaning Procedure

    4. Select the System tab 5. Press the DAC button for any active analyzer ( see image below ) DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 20 ChemLogic cassette out of the way. Next, remove the optic block cover by unscrewing out the two phillips screws (see image below). DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 21 140. Notice there are two fiber optic lenses per point. Both must be cleaned for the best possible results (see images below). DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 22 (see image below). DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 23: Optic System Troubleshooting Procedure

    4. Select the System tab 5. Press the DAC button for any active analyzer ( see image below ) DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 24: Power Verification Procedure

    First, remove the cover for the optic block that is not working properly (see image below). When the cover is removed the power wires will be accessible. Using the DMM, measure the DC voltage between DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 25 Also verify none of the red lights are on, if one is on, this indicates a blown fuse and it must be replaced. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 26: Communication Verification

    Verify that the orange and brown wires are tight and fully inserted into the optic block (see image below). DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 27 PC (see image below). Then confirm all optic block communication cables are securely connected to the interconnect board below the analyzer (see image below). DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 28: Gate Fault Procedure

    Slave gate Slave switch Master gate Master switch DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...
  • Page 29 If the issue cannot be found or resolve using this method please contact DOD Technologies Inc. technical additional support. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 30: Flow Check Procedure

    Check for any 0 values. This would indicate a communication issue between the flow system boards and the PC. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 31 5.3V at the red (+) and black (-) wires. Also, verify that all interconnect board connections are secured. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 32 0 values please contact DOD Technologies technical support. A17-32 A1-16 B17-32 B1-16 C1-16 C17-32 DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...

  • Page 33: Flow Path Verification Procedure

    If flow is still low, locate the filter at the end of each sample line and verify that it’s not clogged. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 34: I/O Verification Procedure

    This procedure should be followed when any of the following messages appear in the CL96 Event Log: 1. Output Module Communication Error (Service Fault) 2. Output module failure or not installed (Service Fault) DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 35 PC and modules by unplugging the green cable in the control box (see image below) and plugging it back DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 36 Each bank of modules will have (1) EK1101 module at the beginning with (3) address dials ( see image below). DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 37: Hardware Replacement

    To replace a CL96 optic block, follow these steps: 1. Open the gate 2. Remove power from the analyzer by unplugging the green connector. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 38 4. Remove the (2) screws holding down the optic block. 5. Remove all (8) tubes and pay attention to the orientation for reinsertion. (See image below) DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 39 8. Install the new block by following the steps in reverse order 9. Confirm the address on the new block matches the address on the old block. DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...

  • Page 40: Pump Replacement

    8. Fully insert the inlet and exhaust tubing 9. Reconnect the (2) pin power connector. Inlet and exhaust tubing DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com...
  • Page 41 Page 38 of 44 Power Connector # 10 Nuts DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...

  • Page 42: Appendices

    Page 39 of 44 Appendices Appendix A: Control Wiring DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...

  • Page 43: Appendix B: Pump Panel Wiring

    Page 40 of 44 Appendix B: Pump Panel Wiring DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...

  • Page 44: Appendix C: Analyzer Wiring

    Page 41 of 44 Appendix C: Analyzer Wiring DOD Technologies, INC • 675 Industrial Dr. Bldg. A • Cary, IL 60013 • Phone (815) 788-5200 • Fax (815) 788-5300 DC-MAN-CL96Servicemanual www.dodtec.com Innovative Life Safety Systems & Services...

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