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DOD Technologies ChemLogic Revive CL4R Operating Manual

4-point continuous gas detector
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ChemLogic
Revive™ CL4R
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4-Point Continuous Gas Detector
Operating Manual

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Summary of Contents for DOD Technologies ChemLogic Revive CL4R

  • Page 1 ChemLogic Revive™ CL4R ® 4-Point Continuous Gas Detector Operating Manual...
  • Page 2 ChemLogic® Revive™ CL4R Operating Manual  DOD Technologies, Inc. 675 Industrial Drive Bldg. A. Cary, IL 60013 solutions@dodtec.com Phone 815.788.5200 • Fax 815.788.5300 DODtec.com DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023 815-788-5200 Page 2 solutions@dodtec.com...

  • Page 3: Table Of Contents

    ChemLogic® Revive™ CL4R Operating Manual Table of Contents Chapter 1 – Overview ..................................6 1.1 Introduction ................................... 6 1.2 Sampling and Monitoring ..............................6 1.3 Theory of Operation ................................6 Chapter 2 – Features & Layout ..............................7 2.1 Features ....................................7 2.1.1 Warning Labels, Descriptions, &...
  • Page 4 ChemLogic® Revive™ CL4R Operating Manual 3.9 Loading the ChemLogic ® Cassette ............................ 18 3.10 Powering ON/OFF ................................18 Chapter 4 - Setup & Configuration ............................... 19 4.1 Set System Date and Time ..............................19 4.2 Gas Selection..................................19 4.3 Alarm Settings ..................................19 4.4 Output Relays ..................................
  • Page 5 ChemLogic® Revive™ CL4R Operating Manual Chapter 7 – Service & Support ..............................40 Appendix A – Parts & Accessories.............................. 41 Appendix B – Communication Protocols ........................... 42 Appendix C – System Specifications ............................45 Appendix D – System Event Messages ............................46 Appendix E –...

  • Page 6: Chapter 1 - Overview

    The CL4R can monitor and detect a wide range of gases. It is designed for continuous and prolonged operation when routine maintenance is performed (per factory specifications). The CL4R employs DOD Technologies’ ChemLogic colorimetric technology, utilizing ChemLogic cassettes with chemically infused tape for fast and accurate gas detection.

  • Page 7: Chapter 2 - Features & Layout

    ChemLogic® Revive™ CL4R Operating Manual Chapter 2 – Features & Layout 2.1 Features 2.1.1 Warning Labels, Descriptions, & Danger Zones The table below references the warning labels (with descriptions) that may be encountered while operating and servicing the ChemLogic CL4R continuous gas detection system. WARNING: Hot Surface.

  • Page 8: Touch Screen Display

    ChemLogic® Revive™ CL4R Operating Manual Please be aware of the following danger zones on the ChemLogic CL4R continuous gas detection system. Each zone contains warning labels for operator safety. This danger zone is in the service access point of the unit. Users should be cautious of hot surfaces and the potential of electric shock.

  • Page 9: Chemlogic Cassette

    5.3.4 regarding flow adjustment. 2.1.5 ChemLogic Cassette The ChemLogic cassette is accessible from the top of the unit. The CL4R system utilizes DOD Technologies’ exclusive ChemLogic colorimetric technology. Only use ChemLogic cassettes specifically offered for the CL4R system. Refer to Section 6.1 for additional details regarding cassette installation and replacement.

  • Page 10: External Layout

    ChemLogic® Revive™ CL4R Operating Manual 2.2 External Layout Flow tubing & exhaust A/C Power & Switch (Rear) quick-connect system Maintenance Cover (Rear) ChemLogic® CL4R Cassette Take-up reel Rack Mounting Rack Mounting Bracket Bracket Flow adjustment knobs Touch Screen LCD Display USB 3.0 Drive Figure 2.1 2.2.1 Maintenance Area...

  • Page 11: Internal Layout

    ChemLogic® Revive™ CL4R Operating Manual 2.3 Internal Layout 2.3.1 Service Area Internal access to the CL4R for installation and service is performed by removing the top cover (rear) secured by Phillips screws. Figure 2.3 shows the internal layout of the CL4R with the top cover open. IMPORTANT: The top cover should remain closed and secured except when servicing critical components.

  • Page 12: Password Security

    ChemLogic® Revive™ CL4R Operating Manual 2.4 Password Security Access to many of the features is controlled through password protection which is entered through the screen displayed in Figure 2.4. Figure 2.4 When an attempt is made to access a screen that is password protected, the screen shown in Figure 2.4 will appear (see important note below).

  • Page 13: Chapter 3 - Installation

    The tabletop is the basic, stand-alone configuration that is used throughout this manual to show instrument operation. Rack configurations require a separate enclosure. Please contact DOD Technologies if assistance is required using a wall mount or rack kit (user-supplied rack) configuration.
  • Page 14 ChemLogic® Revive™ CL4R Operating Manual Front Figure 3.1 Side Figure 3.2 Rear Figure 3.3 DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023 815-788-5200 Page 14 solutions@dodtec.com...

  • Page 15: Sample Tubing

    Sample tubing is connected to the CL4R from the back of the CL4R. All sample tubes are 1/4” OD x 3/16” ID Teflon FEP (500 ft max length) which may be purchased from DOD Technologies, Inc. (See Appendix A). Fully depress each sample tube into the proper hole when attaching. To detach the tube, push on the collet and pull the tubing out.

  • Page 16: Sampling Environment

    CL4R. 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 1/4”...

  • Page 17: Sample Line Particulate Filter Installation

    Properly ventilate the exhaust line, which should not exceed 50 feet (15 m) in length. If longer distances are required, contact DOD Technologies. If multiple CL4R units are installed in the same location, use a separate line for each exhaust outlet •...

  • Page 18: Loading The Chemlogic ® Cassette

    ChemLogic® Revive™ CL4R Operating Manual 3.9 Loading the ChemLogic Cassette ® For ChemLogic® cassette loading procedures, see Section 6.1. WARNING Be sure to install the correct ChemLogic® Appendix A cassette (See for part number information.) Make sure the label on the ChemLogic® cassette and the label on the analyzer correspond.

  • Page 19: Chapter 4 - Setup & Configuration

    ChemLogic® Revive™ CL4R Operating Manual Chapter 4 - Setup & Configuration 4.1 Set System Date and Time See Section 5.3.2 4.2 Gas Selection Each point on the CL4R must be setup for the appropriate gas and configured accordingly. See Section 5.3.1 for information on selecting the gas for each point.

  • Page 20: Install New Chemlogic Cassette

    ChemLogic® Revive™ CL4R Operating Manual 4.6 Install New ChemLogic Cassette See Section 6.1 for installation instructions. 4.7 Setup Complete Enter analysis. DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023 815-788-5200 Page 20 solutions@dodtec.com...

  • Page 21: Chapter 5 - Basic Operation

    ChemLogic® Revive™ CL4R Operating Manual Chapter 5 – Basic Operation 5.1 CL4R 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 22: Initialization

    ChemLogic® Revive™ CL4R Operating Manual 5.2 Initialization When the CL4R is powered on it will begin with an initialization screen, followed by the start-up screen (Figure 5.2). Figure 5.2 If the operator touches the ‘Setup Menu’ button before the ‘Seconds to Analysis’ timer reaches zero, the Setup screen will appear.

  • Page 23: Setup / Main Menu

    ChemLogic® Revive™ CL4R Operating Manual Figure 5.3.2a1 Figure 5.3.2a2 Note, you must first select a box or open field prior to entering an alphanumeric keyboard command. The ‘moveable’ keyboard is recommended as it provides the most flexibility to access the boxes/fields. Select the “X”...

  • Page 24: Gas & Alarm Settings Menu

    ChemLogic® Revive™ CL4R Operating Manual 5.3.1 Gas & Alarm Settings Menu Touching the ‘GAS & ALARM SETTINGS’ button on the setup screen brings up the first screen shown in Figure 5.3.1, which displays the configuration of points 1-4. Touching the ‘DONE’ button will then return to the SETUP screen.

  • Page 25: Set Date/Time

    ChemLogic® Revive™ CL4R Operating Manual Touching the ‘SELECT GAS’ button brings up the gas selection menu from which you may either select a new gas or select the ‘Cancel’ button. All available gas calibrations for the current gas family will be shown. 5.3.2 Set Date/Time Enter a valid password to proceed after selecting the ‘SET DATE/TIME’...

  • Page 26: Load Tape

    During this time a ‘CALIBRATING OPTICS’ window will appear. IMPORTANT : If you choose ‘NO’ when asked to calibrate the optics, the CL4R may not function properly. Contact DOD Technologies for more information. DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023...

  • Page 27: Flow Adjustment

    ChemLogic® Revive™ CL4R Operating Manual Upon completion of the process, either a notice of verification or message with the recommended adjustment will be provided. If successful touch the “OK” button to return to the setup menu. If unsuccessful, an error screen will appear with further instructions.

  • Page 28: Calibration Factors

    ChemLogic® Revive™ CL4R Operating Manual 5.3.5 Calibration Factors Select the ‘CALIBRATION FACTORS’ button on the Setup screen to bring up the screen in Figure 5.3.5. Note, this screen requires an administrator password for access. Contact DOD (see Chapter 7) for information on the use of Calibration Factors.
  • Page 29 ChemLogic® Revive™ CL4R Operating Manual Output Relay Test Figure 5.3.6 DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023 815-788-5200 Page 29 solutions@dodtec.com...

  • Page 30: Factory Settings

    • Data Backup • This section is reserved for technical service and requires a service password. Contact DOD Technologies (see Section 7) for service information. 5.3.8 Event History Touching the ‘VIEW LOGS’ button on the setup screen brings up the ‘EVENTS’ screen shown in Figure 5.3.8.

  • Page 31: Concentration Log

    ChemLogic® Revive™ CL4R Operating Manual Green Normal operation messages Yellow Fault (Maintenance) messages Blue Informational display messages – non-critical Orange Critical (Fault) Service messages Gas alarm messages Table 5.3.8 Touch the ‘BACK’ button to return to the setup menu. 5.4 Concentration Log Touching the ‘CONC’...

  • Page 32: Concentration Configuration

    ChemLogic® Revive™ CL4R Operating Manual 5.4.1 Concentration Configuration Selecting FACTORY SETTINGS  CONFIGURE brings up the concentration configuration screen shown in Figure 5.4.1. A password is required to access this screen. Four levels of logging are available depending on your needs: 1.
  • Page 33 ChemLogic® Revive™ CL4R Operating Manual Return to Setup See Section 5.3.8 Reset active faults & alarms Analysis Screen Analysis Point Detail Alarm Level settings Status Bar: Normally blank “DISABLED’ Gas Concentration “GAS DETECTED” “BEYOND FULL SCALE” Color indicates status: Green – Normal Touch/click to bring up Yellow –...

  • Page 34: Point Detail Screen

    ChemLogic® Revive™ CL4R Operating Manual 5.5.1 Point Detail Screen Touching a point # on the analysis screen will bring up the point detail screen shown in Figure 5.5.1. Trend graph of gas concentration on this point Current Flow Setting Point status Concentration Alarm 1 &...

  • Page 35: Time Weighted Average (Twa)

    ChemLogic® Revive™ CL4R Operating Manual 5.6 Time Weighted Average (TWA) Touching the ‘TWA’ button on the concentration log screen brings up the TWA screen shown in Figure 5.6. Peak value reached in cycle Figure 5.6 The first screen displays the current TWA information including the minutes and seconds elapsed since the cycle started.

  • Page 36: Chapter 6 - Maintenance

    ChemLogic® Revive™ CL4R Operating Manual Chapter 6 – Maintenance It is recommended for complete safety that the ChemLogic CL4R continuous gas detection system be serviced on-site every 6-12 months by a certified DOD Service Technician or by submitting the unit to the manufacturer for routine maintenance.

  • Page 37: End-Of-Line Particulate Filters

    ChemLogic® Revive™ CL4R Operating Manual 6. Fold the end of the tape and insert into the slot in the empty cassette reel. Be sure the tape is wound clockwise around the take-up reel. Upper cassette reel Top tape guide Capstan / Rubber roller Optic Blocks Bottom tape guide Lower cassette reel...
  • Page 38 ChemLogic® Revive™ CL4R Operating Manual - Filter For Corrosive Gases - Disposable Filter For – Disposable Filter For Corrosive Gases Non-Corrosive Gases Recommended membrane replacement every 1 month. Internal Recommended replacement every 3-6 housing body should be cleaned months. annually. Part Number: 780248 Part Number:...

  • Page 39: Flow Adjustment

    ChemLogic® Revive™ CL4R Operating Manual 6.3 Flow Adjustment Each channel should be adjusted whenever a new ChemLogic Cassette or particulate filter is installed. See Section 5.3.4. 6.4 Apply Grease The cam attached to the gate motor should be greased every 6-12 months to prevent wear. Apply a small amount of number 2 type petroleum or synthetic grease (such as McMaster Carr #1378K27) to the rounded portion of the cam.

  • Page 40: Chapter 7 - Service & Support

    Cary, IL 60013 E-mail us at: solutions@dodtec.com Visit our website: DODtec.com For permanent discontinuation: Discontinued units may be eligible for recycling. Please contact DOD Technologies for additional information and instructions for arranging safe return of your equipment. DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023 815-788-5200 Page 40 solutions@dodtec.com...

  • Page 41: Appendix A - Parts & Accessories

    ChemLogic® Revive™ CL4R Operating Manual Appendix A – Parts & Accessories Replacement ChemLogic Cassettes ® Part # Description 120-Day Cassettes CL4R Phosgene 120-Day ChemLogic Cassette 1-200-052 Gas Detected: COCl2 CL4R Hydride 120-Day ChemLogic Cassette 1-300-052 Gas Detected: AsH3, B2H6, GeH4, H2S, H2Se, PH3, SiH4 CL4R Mineral Acid SG 120-Day ChemLogic Cassette 1-420-052 Detects: BF3, C4F6, CH2F2, CH3F, HBr, HCl, HF...

  • Page 42: Appendix B - Communication Protocols

    ChemLogic® Revive™ CL4R Operating Manual Appendix B – Communication Protocols CL4R MODBUS/TCP Data Option MODBUS/TCP data contains concentrations, alarm levels, and gas types for all points in addition to machine fault, general alarm, and misc bit indicators. Alarm Levels and Concentration are passed as unsigned integers.
  • Page 43 ChemLogic® Revive™ CL4R Operating Manual 4x MODBUS Format Size Description Address 40139 Numeric 16 Bit (Word) Pt 3 - Gas Alarm 2 40140 Numeric 16 Bit (Word) Pt 4 - Gas Alarm 2 40145 Numeric 16 Bit (Word) Pt 1 - Enabled 40146 Numeric 16 Bit (Word)
  • Page 44 ChemLogic® Revive™ CL4R Operating Manual Gas ID Range Label Gas ID Range Label AsH3(0-500)ppb COCl2(0-3250)ppb B2H6(0-1000)ppb CL2(0-5000)ppb PH3(0-1500)ppb CL2(0-3200)ppb SiH4(0-50)ppm C5F8(0-15)ppm H2S(0-25)ppm Br2(0-1000)ppb COCl2(0-1000)ppb MIC(0-100)ppm COCl2(0-4000)ppb N2H4(0-500)ppb AceticAcid(0-50)ppb NO2(0-30)ppm AsH3(0-500)ppb F2(0-3200)ppb B2H6(0-1000)ppb NF3(0-20)ppm PH3(0-1500)ppb NF3(0-20)ppm MIC(0-10)ppm HCN(0-2500)ppb H2S(0-20)ppm COS(0-20)ppm NH3(0-75)ppm NO2(0-100)ppm DMDC(0-500)ppb PH3(0-300)ppb...

  • Page 45: Appendix C - System Specifications

    ChemLogic® Revive™ CL4R Operating Manual Appendix C – System Specifications Physical Dimensions Height 8.75” (222 mm) Width 17” (432 mm) Depth 17.75” (451 mm) Weight Approx. 40 lbs. (18.14 kg) Tubing 1/4” OD x 3/16” ID x polyethylene, polypropylene or Teflon, Exhaust Line (1) 50 ft.

  • Page 46: Appendix D - System Event Messages

    ChemLogic® Revive™ CL4R Operating 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...
  • Page 47 ChemLogic® Revive™ CL4R Operating Manual Event Code Message Corrective Action 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...

  • Page 48: Appendix E - Gas Specifications

    ChemLogic® Revive™ CL4R Operating Manual Appendix E – Gas Specifications Alarm Alarm Response ChemLogic Name Units Time TLV Cassette # Default Default (T100)*secs 10000 10000 20000 Acetic Acid CH3CO2H 1-700-052 Ammonia Arsenic Pentafluoride^ AsF5 (HF) Arsenic Trichloride^^ AsHCl3 (HCl) Arsenic Trifluoride^ AsF3 (HF) 1-300-052 Arsine...
  • Page 49 ChemLogic® Revive™ CL4R Operating Manual Alarm Alarm Response ChemLogic Name Units Time TLV Cassette # Default Default (T100)*secs 1-420-052 Hydrogen Chloride 1-420-052 Hydrogen Chloride 3250 1000 1-420-052 Hydrogen Chloride 1-420-052 Hydrogen Bromide 298.2 2500 4700 1000 Hydrogen Cyanide 1-420-052 Hydrogen Fluoride 1-420-052 Hydrogen Fluoride 1-300-052...
  • Page 50 Velcorin DMDC * Additional ranges may be available and are subject to change. Please see specific product brochure or contact DOD Technologies. ** Requires pyrolyzer option for detection ^ Compounds which hydrolyze to HF ^^ Compounds which hydrolyze to HCl ^^^ Compounds which hydrolyze to HBr DODtec.com...

  • Page 51: Appendix F - Chemlogic Cassettes

    ChemLogic® Revive™ CL4R Operating Manual Appendix F – ChemLogic Cassettes ChemLogic Cassettes are designed for use in colorimetric based gas monitoring systems. Since this is a particular end-use function that does not release or result in exposure to hazardous chemicals under normal use, Material Safety Data Sheets (MSDS) are not required.

  • Page 52: Appendix G - Optic Block Cleaning Procedure

    ChemLogic® Revive™ CL4R Operating Manual Appendix G – Optic Block Cleaning Procedure The CL4R 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 53: Advanced Optics Cleaning

    2) Using a cotton swab and alcohol (you may have to trim the cotton swab to fit) clean each channel that has a DAC above 140. (Figure Figure 6 3) Repeat above steps 7-11 4) If the DAC values still have not improved contact DOD Technologies Technical Service at 815-788- 5200. DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023...

  • Page 54: Appendix H - 4-20Ma + Relay Option Installation

    ChemLogic® Revive™ CL4R Operating Manual Appendix H – 4-20mA + Relay Option Installation H.1 4-20mA + Relay Option Overview Materials required with this option include: Qty 1: Coupler Terminal for EtherCAT Extension Hot Connect (2-200-070) Qty 2: 2-Channel Analog Output Terminal 0-20 mA (2-200-099) Qty 2: Output Module, 8-Point 24 VDC Sink EtherCAT, 0.5A individual 3.0A max (2-200-068) Qty 14: Form C Relays Screw terminals: max torque 0.5 Nm, strip length 10mm, max wire size 14)
  • Page 55 ChemLogic® Revive™ CL4R Operating Manual 2. The following diagrams shows where to terminate each relay into the output modules and the purpose of those outputs. 3. 24V needs to be brought to the coupler terminal, terminating as shown below: DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023 815-788-5200...
  • Page 56 ChemLogic® Revive™ CL4R Operating Manual 4. The black and yellow wires will tie into the 24V terminal blocks on the inside of the CL4R. 5. One more 24V yellow wire needs to be brough to the A2 terminal on a Form C Relay, the rest of the relays being jumped together on that terminal.

  • Page 57: 4-20Ma + Relay Tabletop Installation

    ChemLogic® Revive™ CL4R Operating Manual H.3 4-20mA + Relay Tabletop Installation 1. For a CL4R installed as a desktop unit, the relay bus will be mounted to the top plate of the CL4R itself as shown below: 2. The ethernet cable and 24V wires routing around the back, and through a grommet. 3.

  • Page 58: 4-20Ma + Relay Rack Mount Installation

    ChemLogic® Revive™ CL4R Operating Manual H.4 4-20mA + Relay Rack Mount Installation 1. To install the CL4R into a legacy rack, the relay bus should be secured to the same legacy CM4 relay board back plate. See example below. 2. In this scenario, the ethernet cable, and the 24V power will run from the coupler terminal along the tubing and power cable casing into the back of the CL4R.

  • Page 59: Appendix I - Cl4R Pump Installation

    ChemLogic® Revive™ CL4R Operating Manual Appendix I – CL4R Pump Installation I.1 Pump Installation Overview Pumps do not arrive pre-installed and are shipped separately from the CL4R gas detection unit to prevent damage. The pump is intended to be installed by an installation and support technician. Carefully remove the system and pump from the packaging materials.
  • Page 60 ChemLogic® Revive™ CL4R Operating Manual Lift up the upper blue assembly such that it clears the four PEM studs that the four nuts were removed from. Using caution not to damage wiring harnesses/tubing, tilt the assembly so that the DC motor (green box in image below) rests on the power supply.
  • Page 61 ChemLogic® Revive™ CL4R Operating Manual Remove the nut and star washer from the bottom of the enclosure pump PEM stud. The enclosure has a retaining bar secured to the bottom (see images below). Insert the pump lower plate into the retaining bar as shown in images below. Ensure that the plate inserts in the retaining bar and the PEM stud aligns and passes through the hole in the front of the pump plate.
  • Page 62 ChemLogic® Revive™ CL4R Operating Manual Connect the tubing to the pump. RED colored fittings together and GREEN colored fittings together. Ensuring the tubing connections are fully seated. DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023 815-788-5200 Page 62 solutions@dodtec.com...
  • Page 63 ChemLogic® Revive™ CL4R Operating Manual Connect the pump power connector. Observe the proper orientation for the keyed connector. Place the upper blue assembly over the four PEM studs. Ensuring to take care not to damage wiring and tubing. Using a 11/32 (9mm) nut driver install the four nuts from the upper blue assembly (see image below). Re-install the rear cover using a #2 Phillips screwdriver and the three screws (see image below).
  • Page 64 ChemLogic® Revive™ CL4R Operating Manual When ready re-connect power and tubing. Retest Verification Fully inspection the system for proper wiring and tubing connections. Verify all wiring and tubing has been properly connected. Retest to ensure install was performed correctly. DODtec.com DC-ITD-CLM4MAN_2023_A REV 6/13/2023 815-788-5200...

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