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ChemLogic® Revive™ CL4R Operating Manual EMC Considerations Your DOD Technologies continuous gas monitor has been designed to comply with Electromagnetic Compatibility (EMC) standards applicable at the time of its manufacturing. The design includes filtering, shielding and bypassing techniques. At the time of certification, simulated customer Input/ Output (I/O) schemes were tested.
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ChemLogic® Revive™ CL4R Operating Manual Table of Contents Chapter 1 – Overview ..................................8 1.1 Introduction ................................... 8 1.2 Sampling and Monitoring ..............................8 1.3 Theory of Operation ................................8 Chapter 2 – Features & Layout ..............................9 2.1 Features ....................................9 2.1.1 Warning Labels, Descriptions, &...
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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.
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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.
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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. This danger zone refers to the top of the pump on the inside of the unit.
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All options added should only be used per their intended design. Any modifications made or procedures taken outside the intended use may void the warranty and/or produce unexpected results. DOD product is considered process control equipment. Contact DOD Technologies for additional requests regarding SIL (Safety Integrity Level) rating.
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A watchdog relay (RY12) indicates power loss or a CPU failure. • Note: The legacy PCB is not provided by DOD Technologies as the intent is to utilize the existing legacy enclosure. Contact us for alternate I/O relay options for use inside the existing enclosure.
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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 USB 3.0 Drive Flow adjustment knobs Touch Screen LCD Display Figure 2.1 2.2.1 Maintenance Area The maintenance area provides easy access for changing ChemLogic cassettes in the CL4R.
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ChemLogic® Revive™ CL4R Operating Manual 2.3 Internal Layout 2.3.1 Lock Out Tag Out (LOTO) Process 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.
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ChemLogic® Revive™ CL4R Operating Manual 2.4 Password Security Access to many features is controlled through password protection entered through the screen displayed in Figure 2.4. Figure 2.4 (Per software 24.0222 Build 299 or higher. Contact us if assistance is required for earlier software versions.) 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).
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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.
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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 (400 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.
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ChemLogic® Revive™ CL4R Operating Manual CL4R rear view connections. Figure 3.5 3.3 Sampling Environment Before installing the CL4R, review and determine if the sampling environment locations has excessive dust or moisture. Use an external filter at the end of all sample lines. See Appendix A for selection of appropriate filter type for the target gas.
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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” OD x 3/16” ID tubing with a maximum length of 50 ft. Polyethylene, polypropylene or Teflon may be used.
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ChemLogic® Revive™ CL4R Operating Manual Nut Driver (9 mm (about 0.35 in) Nut Driver) will be required. Follow the pump installation procedures to proceed. 3.7.1 Pump Installation Procedure Prior to installation, verify power is disconnected. Using a #2 Phillips screwdriver, remove the three screws from the upper rear cover (see image below).
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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.
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ChemLogic® Revive™ CL4R Operating Manual Install the following parts in the order listed: 1. Place the star washer over the PEM stud. 2. Place the terminal ring from the pump green wire over the PEM stud. 3. Tighten the nut on the enclosure pump PEM stud using a 11/32 (9mm) nut driver. DODtec.com DC-TEC-MAN-CL4R_2024_I REV 12/13/2024...
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ChemLogic® Revive™ CL4R Operating Manual Connect the tubing to the pump. RED colored fittings together and GREEN colored fittings together. Ensure the tubing connections are fully seated. Connect the pump power connector. Observe the proper orientation for the keyed connector. DODtec.com DC-TEC-MAN-CL4R_2024_I REV 12/13/2024...
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3.8.1 Exhaust Line Installation Guide 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 Do not crimp exhaust lines, place them in an area where weight could collapse the tubing, or bend them •...
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ChemLogic® Revive™ CL4R Operating Manual 3.8.2 Exhaust Tubing Specifications The instrument includes 50 feet (15 m) of 3/16-inch (4.7 mm) I.D. x 1/4-inch (6.35 mm) O.D. polypropylene tubing. 3.9 Loading the ChemLogic ® Cassette For ChemLogic cassette loading procedures, see Section 6.1.
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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 set up for the appropriate gas and configured accordingly. See Section 5.3.1 for information on selecting the gas for each point.
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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-TEC-MAN-CL4R_2024_I REV 12/13/2024 Page 28 815-788-5200...
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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.
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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.
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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”...
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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.
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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’...
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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-TEC-MAN-CL4R_2024_I REV 12/13/2024...
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ChemLogic® Revive™ CL4R Operating Manual Upon completion of the process, either a notice of verification or a 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. Verify that the cassette is installed and aligned correctly by using the ‘OPEN/CLOSE’...
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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 that this screen requires an administrator password for access. Contact DOD (see Chapter 7) for information on the use of Calibration Factors.
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• 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.
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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’...
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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.
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ChemLogic® Revive™ CL4R Operating Manual 5.5 Analysis Mode Figure 5.5 shows the main analysis screen which is entered either automatically during power on or by touching the ‘START ANALYSIS’ button on the setup screen. It also shows the main analysis screen with a detailed view of the information on point 3.
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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 &...
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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.
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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.
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ChemLogic® Revive™ CL4R Operating Manual 6. Fold the end of the tape and insert it 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...
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ChemLogic® Revive™ CL4R Operating Manual - Filter For Corrosive Gases - Disposable Filter For – Disposable Filter For Corrosive Gases Non-Corrosive Gases Recommended membrane replacement every 30 days, Recommended replacement every 3-6 depending on conditions. The months, depending on conditions. internal housing body should be Part Number: 780248...
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ChemLogic® Revive™ CL4R Operating Manual 6.4 Preventative Maintenace 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.
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Follow all local regulations when disposing of electrical components and systems. Discontinued units may be eligible for recycling. Please contact DOD Technologies for additional information and instructions for arranging the safe return of your equipment.
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ChemLogic® Revive™ CL4R Operating Manual Appendix B – Data Communications 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.
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ChemLogic® Revive™ CL4R Operating Manual Description Reserved Reserved Power On Reserved Reserved Reserved Reserved Reserved 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...
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ChemLogic® Revive™ CL4R Operating Manual Appendix C – System Specifications Physical Dimensions Height 8.625” (219 mm) Width 17” (432 mm) Depth 17.75” (451 mm) Weight Approx. 45 lbs. (20.4 kg), 53 lbs. (24 kg) with pyrolyzer Tubing 1/4” OD x 3/16” ID x polyethylene, polypropylene, or Teflon, Exhaust Line (1) 50 ft.
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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...
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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...
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Appendix E – Gas Specifications Click the following link to review a list of detectable gases and available system calibrations: ChemLogic Revive CL4R Detectable Gas List This list can also be accessed and downloaded at DODtec.com by visiting the ‘Detectable Gases’ section in the corresponding product page(s).
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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.
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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.
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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 6) 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-TEC-MAN-CL4R_2024_I...
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ChemLogic® Revive™ CL4R Operating Manual Appendix H – 4-20mA + Relay Option Installation WARNING : Options 2-510-007-SA, 2-510-013-4, and 2-510-013-14 are only intended for use in specific setups. Those that procure these options are not using the CL4R in a rack-mounted or tabletop setup/installation.
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ChemLogic® Revive™ CL4R Operating Manual Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Output Output Output Output Output Output Output Output Output Output 2 Output 3 Output 4 Output Output Point Point Point Point Point Point Point...
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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.
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ChemLogic® Revive™ CL4R Operating Manual 7. X256: 6, X16:0, X1:1 8. Once this is done, the relay option is now installed and ready to be configured on the CL4R. 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.
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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.
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ChemLogic® Revive™ CL4R Operating Manual Appendix I – CL4R Flow Diagrams I.1 Single Point Flow Diagram I.2 Single Point Flow Diagram - Pyrolyzer DODtec.com DC-TEC-MAN-CL4R_2024_I REV 12/13/2024 Page 65 815-788-5200...
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ChemLogic® Revive™ CL4R Operating Manual Appendix K – CL4R Software Update Procedure 1. Unzip the CL4R_Update_23.0522.zip file to the root of a USB drive. 2. The USB should have the correct files on it and look like the picture below. 3.
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ChemLogic® Revive™ CL4R Operating Manual 4. On the CL4R main menu, press “Factory Settings” and enter password “740047” when prompted. 5. Then, enter Machine Setup. DODtec.com DC-TEC-MAN-CL4R_2024_I REV 12/13/2024 Page 72 815-788-5200...
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ChemLogic® Revive™ CL4R Operating Manual 6. Select Update Software and confirm. The update will now run. 7. Select the appropriate Configuration (found on the About screen) and select Next. DODtec.com DC-TEC-MAN-CL4R_2024_I REV 12/13/2024 Page 73 815-788-5200...
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ChemLogic® Revive™ CL4R Operating Manual 8. You may now press “Start Update.” 9. Allow the update to Complete, then restart the CL4R. 10. The CL4R is now updated and correctly configured. DODtec.com DC-TEC-MAN-CL4R_2024_I REV 12/13/2024 Page 74 815-788-5200...
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ChemLogic® Revive™ CL4R Operating Manual Appendix L – CL4R Pyrolyzer Operation L.1 Overview The ChemLogic CL4R Pyrolyzer Option is specially designed to detect special gases using elevated temperature to “crack” the gases into ChemLogic® detectable gases. Current detectable gases are: Hexafluoro cyclobutene (C4F6) 0-40 ppm, Nitrogen Trifluoride (NF3) 0-20 ppm, Octafluoro cyclopentene (C5F8) 0-15 ppm.
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ChemLogic® Revive™ CL4R Operating Manual L.3 Operation Be sure the CL4R is powered on before operation. No special configuration is necessary for the pyrolyzer option after the gas tables are loaded at the factory. L.3.1 Filters End-of-line filters are recommended for all sample tubing on the CL4R (reference section 6.2 End-Of-Line Particulate Filters).
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