ChemLogic 1
Single Point Continuous Gas Monitor
User’s Manual
DECLARATION OF CONFORMITY
DOD TECHNOLOGIES INC.
740 McArdle DR. Unit C
Crystal Lake, Illinois 60014
We declare under our sole responsibility that the product described as:
ChemLogic 1 (CL1)
Complies with the requirements of the Directives:
- Machinery Directive 98/37/EC (amended);
- Low Voltage Directive 2006/95/EC
- Electromagnetic Compatibility Directive 2004/108/EC
Standards considered:
EN 12100-1, EN 12100-2, EN 60204-1, EN 61000-6-2, EN 61000-6-4
Date: 12 / 3 / 2007 At: 10:00 am
Daniel ODonnell
Daniel O'Donnell
ChemLogic 1 User’s Manual
Default Passwords
Setup Menu
0
Service Menu
1234
DOD Technologies, INC
www.dodtec.com
740 McArdle Dr. • Unit C
Crystal Lake, IL 60014
Phone 815.788.5200 • Fax 815.788.5300
TABLE OF CONTENTS
IMPORTANT ............................................................................................................................................... 1
CHAPTER 1 - OVERVIEW........................................................................................................................ 2
1.1 Introduction....................................................................................................................................... 2
1.2 Sampling and Monitoring ................................................................................................................. 2
1.3 Flow Connections.............................................................................................................................. 2
1.4 Electrical Connections ...................................................................................................................... 2
1.5 Theory of operation........................................................................................................................... 2
CHAPTER 2 - FEATURES ......................................................................................................................... 3
2.1 External Layout................................................................................................................................. 3
2.1.1 Maintenance door .......................................................................................................................... 3
2.1.2 Keypad & Display ........................................................................................................................... 3
2.1.3 ChemLogic tape and Take-up Reel................................................................................................ 3
2.1.4 Gas Inlet/Exhaust........................................................................................................................... 3
2.1.5 A/C Power & Switch....................................................................................................................... 4
2.1.6 14 Pin I/O Connector ..................................................................................................................... 4
2.2 Maintenance area.............................................................................................................................. 4
2.3 Internal Layout – Service area ......................................................................................................... 4
2.5 Micro Secure Digital (SD) card ........................................................................................................ 5
CHAPTER 3 - INSTALLATION................................................................................................................ 6
3.1 Selecting a location ........................................................................................................................... 6
3.2 Mounting ........................................................................................................................................... 6
3.3 Sample Tubing .................................................................................................................................. 8
3.3.2 End of line particulate filters ......................................................................................................... 8
3.4 Exhaust tubing .................................................................................................................................. 8
3.5 A/C Power.......................................................................................................................................... 8
3.6 Output Wiring.................................................................................................................................... 8
CHAPTER 4 – SETUP & CONFIGURATION......................................................................................... 9
CHAPTER 4 – SETUP & CONFIGURATION....................................................................................... 10
CHAPTER 5 – BASIC OPERATION ...................................................................................................... 11
5.1 Using the keypad ............................................................................................................................. 11
5.2 Alarm & Fault screens .................................................................................................................... 12
CL1 Menu Overview.............................................................................................................................. 13
5.3 Power on Initialization.................................................................................................................... 13
5.4 Main Menu ...................................................................................................................................... 13
5.4.a Start Analysis (Figure 5.7)........................................................................................................... 14
5.4.b System Faults (Figure 5.8)........................................................................................................... 15
5.4.c Gas Alarms (Figure 5.9)............................................................................................................... 15
5.4.d Gate & Tape (Figure 5.10)........................................................................................................... 15
5.4.e Alarm Levels (Figure 5.11) .......................................................................................................... 15
5.4.f Event/Alarm History (Figure 5.12) ............................................................................................. 16
5.4.g Test Alarms (Figure 5.13) ............................................................................................................ 16
5.5 Setup Menu (Figure 5.14)............................................................................................................... 17
5.5.a Main Menu ................................................................................................................................... 17
5.5.b Tape Saver (Figure 5.15) (Default configuration : Disabled) .................................................... 17
5.5.c Latching Relays (Figure 5.17) (Default configuration : ON)................................................... 18
5.5.d Enable Pumps (Figure 5.18) (Default configuration : Enabled) ............................................... 19
5.5.e Enable Points (Default configuration : Only available on CL2) ................................................ 19
5.5.f Energized Alarm Relays (Figure 5.19) (Default configuration : Off) ....................................... 19
5.5.g Idle Timeout (Figure 5.20) (Default configuration : 45 Minutes)........................................... 19
5.5.h Date/Time (Figure 5.21) .............................................................................................................. 20
5.5.i Test 4-20ma (Figure 5.22) ............................................................................................................ 20
5.5.i Select Gas (Figure 5.24)............................................................................................................... 20
5.5.j Conc. Logging (Figure 5.25) ........................................................................................................ 20
5.6.a Main Menu ................................................................................................................................... 22
5.6.b Optic Calib (Figure 5.26) ............................................................................................................. 22
5.6.c Passwords(Figure 5.27)................................................................................................................ 22
5.6.d Optic Config ................................................................................................................................. 22
5.6.e Status............................................................................................................................................. 23
5.6.f Clear History (Figure 5.28) .......................................................................................................... 23
5.6.g Configuration ............................................................................................................................... 23
CHAPTER 6 - MAINTENANCE.............................................................................................................. 24
6.1 Maintenance Door Access............................................................................................................... 24
6.2 Service Door Access ........................................................................................................................ 24
6.3 ChemLogic Paper tape .................................................................................................................... 25
ChemLogic Paper Tape Path ................................................................................................................ 25
6.4 End of line particulate filters .......................................................................................................... 26
6.4 End of line particulate filters .......................................................................................................... 27
6.5 Flow adjustment .............................................................................................................................. 27
6.6 Micro Secure Digital (SD) Card replacement ................................................................................ 27
6.4 End of line particulate filters .......................................................................................................... 28
6.7 Fuse Replacement ........................................................................................................................... 28
6.8 Apply grease periodically ................................................................................................................ 28
APPENDIX A – ACCESSORIES ............................................................................................................. 30
APPENDIX B – I/O CONNECTION DETAIL ....................................................................................... 31
APPENDIX C – TECHNICAL SPECIFICATIONS............................................................................... 32
APPENDIX D - SYSTEM EVENT MESSAGES..................................................................................... 33
APPENDIX E - GAS SPECIFICATIONS ............................................................................................... 36
APPENDIX F – REMOVABLE MEDIA ................................................................................................. 37
F.1 Concentration Log Files (YYMMDD*.CSV) ................................................................................. 37
F.2 Event Log Files (YYMMDD*.CSV) ............................................................................................... 37
F.3 Formatting Micro SD Disks ........................................................................................................... 38
APPENDIX G – CHEMLOGIC CASSETTES........................................................................................ 40
APPENDIX H – OPTIC BLOCK CLEANING PROCEDURE ............................................................ 41
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IMPORTANT
Only trained operators must be allowed to work on the Cl1.
ELECTRICAL HAZARD
The CL1 may only be serviced by trained service personnel.
Contact the manufacturer for more information
.
Be sure to read this manual in its entirety before installing and operating the CL1. Contact the
manufacturer with any questions regarding the installation or use of the CL1.
IMPORTANT : Read Appendix G before handling ChemLogic Cassettes.
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Chapter 1 - Overview
1.1 Introduction
The DOD Technologies ChemLogic 1 (CL1) continuously monitors a single location
(called a point) for toxic and corrosive gas. It responds to gas that exceed 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 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 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 actually be leaking.
The CL1 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 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.
1.3 Flow Connections
Flow connections consist of “quick-connect” ports on the bottom and side of the CL1.
There is one inlet and one exhaust outlet.
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 provides all electrical connections for the outputs and remote reset.
1.5 Theory of operation
The sample flow is diverted across the ChemLogic Tape. The CHEMLOGIC 1 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. The
CHEMLOGIC 1 will then report an appropriate gas concentration reading and/or a gas alarm.
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Chapter 2 - Features
2.1 External Layout
Maintenance Door
Keypad & Display
Exhaust Outlet
Take-up reel
14 pin
I/O Connector
Door latches
(side of unit)
A/C Power & Switch
ChemLogic Tape
Gas tubing inlet
(underside)
Figure 2.1
2.1.1 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.
IMPORTANT: The maintenance door should remain closed and latched except when
changing the ChemLogic tape.
2.1.2 Keypad & Display
The CL1 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.
2.1.3 ChemLogic tape and Take-up Reel
ChemLogic paper tapes are accessed by opening the maintenance door. Refer to chapter 6
regarding tape installation/replacement.
2.1.4 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. 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.
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. IMPORTANT: End of line filters are required. See section 6.4
2.1.5 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.
2.1.6 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. Figure
2.2 shows the internal layout with the access panel open. See section 6.3 for tape installation.
Figure 2.2
2.3 Internal Layout – Service area
Internal access to the CL1 for service uses the latches located on the right side of the front
panel. Figure 2.3 shows the internal layout of the CL1 with the service door open.
DANGER: Turn off the unit and disconnect A/C power to the unit before
opening the Service Door.
The door should be opened by trained service personnel (See section 6.2)
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Output Connection Block
SD Card access door
Easy access
long life pumps
Power Supply
Back of Service Door
Inside w/Service Door
open
Figure 2.3
2.5 Micro Secure Digital (SD) card
The CL1 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.
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Chapter 3 - Installation
3.1 Selecting a location
The CL1 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
♦
Using the shortest possible sample line length will reduce transport times and increase
the response time of the CL1.
♦
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 requires stable temperature and humidity levels within range to operate
properly.
3.2 Mounting
Refer to figure 3.1 for dimensional requirements for wall mount. Be sure the CL1 is properly
secured to the wall.
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Figure 3.1
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3.3 Sample Tubing
Sample tubing connects to the CL1 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).
Gas inlet
on bottom
of CL1
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 must be 1/4”OD x 1/8” ID FEP.
Use of any other tubing may damage the CL1 and/or cause inaccurate gas
concentration readings.
3.3.2 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.
IMPORTANT: The CL1 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.
End of line particulate filters may be purchased from DOD technologies (see appendix A)
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. 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 to increase precision. When not in analysis
the CL1 will output the 2ma calibrated value. There is a maximum of 500 ohm load
impedance on the 4-20ma circuit.
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See Appendix B for a listing of output module connections.
DANGER: Before doing any wiring modifications be sure that power to
the CL18 is disconnected.
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Chapter 4 – Setup & Configuration
Follow this checklist to configure the CL1 for first time operation.
1. ___ Set passwords (section 5.6.c)
2. ___ Set system date and time (section 5.5.g)
3. ___ Gas selection (section 5.5.i)
Appendix E contains the specifications for each gas.
4. ___ Alarm level settings (section 5.4.e)
5. ___ Latching relays (section 5.5.c)
6. ___ Energized Relays (section 5.5.e)
7. ___ Idle Timeout (section 5.5.f)
8. ___ Testing Contacts (section 5.4.g)
9. ___ Adjustment of 4-20 ma (section 5.5.h)
10. ___ Install new ChemLogic tape (section 6.3)
11. ___ Install removable media (section 6.6)
12. ___ Format removable media (Appendix F.3)
13. ___ Tape Saver Mode (TSM section 5.5.b)
14. ___ Grease the Gate Cam (section 6.7)
Setup complete - Ready for monitoring.
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Chapter 5 – Basic Operation
5.1 Using the keypad
The CL1 is controlled using the keypad located around the display. All of the display screens
are accessed through a simple menu system.
Note 2
Note 1
Note 3
Figure 5.1
1) The arrow keys located under the screen are used for two purposes.
a. To navigate through the menus using the
key to select the highlighted
item on the menu. In most cases the key will exit the current screen and
return to the top of the previous menu.
b. To select among multiple data fields on some of the screens for editing.
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.
3) When numeric entry is required on any screen the following procedure is used.
1. Use the arrow keys below the screen to select which field to edit. The currently
selected box will have a dashed line around it.
2. Press the key first
3. Use the numeric/function keys to enter the value
4. Also note the up arrow may be used for +/- and the down arrow may be used for the
decimal point when necessary.
5. Press the key again to complete the entry
NOTE: The key is used to exit analysis and return to the main menu.
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5.2 Alarm & Fault screens
Three types of messages used in the CL1:
1. Alarm messages (level 1 and level 2)
2. System faults (critical faults that terminate and/or prevent analysis)
3. Event messages (warnings, non-critical faults, and various events)
See Appendix D for a description of each message. The history log keeps the most recent 128
messages of any type in memory at all times. All three types of messages are also logged to
the Micro SD card if present.
Various screens are used in the CL1 to show some or all of 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 similar to figure 5.3 will be displayed. Pressing the
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 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 key once will return to the screen in figure 5.2. Pressing the key
again from that screen will return to the previous menu or screen.
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CL1 Menu Overview
Power Up (5.3)
Setup Mode
Auto Analysis Timer
Main Menu (5.4)
Start Analysis
System Faults
Gas Alarms
Gate & Tape
Alarm Levels
Event/Alarm History
Test Alarms
Setup Menu
Service Menu
Setup Menu (5.5)
See Note 1
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
Conc. Logging
Service Menu (5.6)
See Note 2
Main Menu
Optic Calib.
Passwords
Status
Optic Config
Clear History
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 (5.6.c)
5.3 Power on Initialization
When the CL1 is powered on it will begin with an initialization screen (figure 5.4) which is
followed by the restart screen (figure 5.5).
Figure 5.4
Figure 5.5
If the operator touches the 