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DOD Technologies ChemLogic CL96 - User Manual

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ChemLogic
®
CL96
96-Point Continuous Gas Detector
Operating Manual

Table of Contents

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Summary

Chapter 1 Overview

1.1 Introduction

Overview of the CL96 system's monitoring capabilities and technology.

1.2 Theory of Operation

Explains how the CL96 detects gases using optical detection and color change on tape.

1.3 Sampling and Monitoring

Details how the system draws and analyzes sample flow from multiple points.

1.4 Electrical Connections

Mentions knockout panels for external electrical connections on the right side.

Chapter 2 Features

2.1 External Layout & Dimensions

Provides an overview of the CL96's external components and physical dimensions.

2.1.3 Touch Screen Display

Details the 19-inch color LCD touch panel for operation.

2.1.4 Keyed Service Door Access

Explains the keyed lock for restricting internal access.

2.1.8 Maintenance Door

Describes easy access for tape installation and replacement.

2.1.10 Tubing Connections

Explains the quick connection system for sample and exhaust tubing.

2.2 Maintenance Area

Describes access to the maintenance area for tape changing.

2.3 Internal Layout - Service Area

Details internal access via a keyed handle on the front panel.

2.4 Password Security

Explains password protection for accessing features.

2.5 USB Storage

Describes the use of USB drives for storing historical data.

Chapter 3 Installation

3.1 Selecting a Location

Lists conditions and restrictions for choosing an installation location.

3.2 Unloading; Loading & Installation

Provides guidance on safely moving and installing the CL96 unit.

3.3 Sample Tubing

Details sample tubing specifications and connection.

3.3.1 End-of-Line Particulate Filters

Emphasizes the requirement for filters to prevent unit damage.

3.5 A;C Power

Outlines requirements for A/C power connection.

3.6.1 Standard Output Wiring

Details wiring procedures for spring-loaded output connectors.

Chapter 4 Setup & Configuration

4.2 Gas Selection

Describes setting up each point for the appropriate gas.

4.3 Alarm Settings

Information on adjusting alarm settings for selected gases.

4.5 Concentration Logging

Details the three levels of concentration logging.

4.7 USB Storage

Explains the importance and use of USB storage drives.

Chapter 5 General Machine Operation

5.1 Introduction

Overview of touch screen operation and continuous monitoring.

5.2 General Screen Navigation

Explains the main menu and touchscreen interface navigation.

5.3 Initialization

Describes the power-on initialization sequence and auto-analysis.

Chapter 6 The Main Menu

6.1 Main Menu

Explains how the main menu allows start/stop analysis and information access.

6.1.a Analysis

Details how to start the CL96 analysis for active points.

6.1.a.2 Point Trend Detail

Shows how to view detailed information and trends for a selected point.

6.1.b Load Tape

Explains the Load Tape screen for managing cassette tapes.

6.1.c Faults;Events

Describes the Faults/Events screen for viewing recent events.

6.1.d History

Provides access to historical data stored on the USB drive.

6.1.d.1 History -> Concentration Log

Displays recorded concentrations for each point by date.

6.1.d.2 History -> Faults;Events

Shows events that occurred on a specific selected date.

6.1.d.3 History -> TWA

Displays Time-Weighted Average data, selectable by date.

6.1.d.4 History -> Storage

Shows CL96 logging capacity and USB storage drive status.

6.1.d.5 History -> Transfer

Explains transferring historical data to another USB storage disk.

6.1.e. Help

Directs to screens with useful references and information.

6.1.e.1 Help -> Manual

Introduces the interactive CL96 User Manual and PDF access.

6.1.e.2 Help -> Diagrams

Links to technical diagrams for various system components.

6.1.e.3 Help -> Contact DOD

Provides contact information for sales, support, and service.

6.1.e.4 Help -> Configuration

Displays configuration details for Analyzers A, B, and C.

6.1.f Setup

Instructions on how to enter the Setup menu.

6.2 Setup Sub-Menu

Introduces the password-protected configuration menu.

6.2.a Setup -> Point Setup

Screen for configuring individual points on each analyzer.

6.2.b Setup -Adjust Flow

Explains how to adjust pump flow rates for analyzers.

6.2.c.1 Setup -> Outputs -> Alarms

Details how to test and configure output alarms for analyzers.

6.2.c.2 Setup -> Outputs -> Point Alarms

Allows testing and toggling of point alarm outputs.

6.2.c.3 Setup -> Outputs -> 4-20 mA

Configuration screen for 0-20mA analog output calibration.

6.2.c.5 Setup -> Outputs -> Optic Test

Describes the optical strip point alarm test procedure.

6.2.d Setup -> Configure

Main screen for configuring logging and system settings.

Output Contact

Configuration of relay states (energized/de-energized) and fault latching.

Flow Fault Filter

Setting to filter flow faults based on duration.

6.2.e Setup -> Date Time

Interface for setting the system's date and time.

6.2.f Setup-> Passwords

Entry screen for passwords to access settings.

6.3 Factory Setup Sub-Menu

Introduces the factory setup menu for configuration.

6.3.a Setup -> Factory -> System

System configuration options for analyzers, communications, and offsets.

6.3.b Setup -> Factory -> Multi Pt

Configuration for enabling/disabling points across multiple analyzers.

6.3.c Setup -> Factory -> Simulation

Settings for simulating analyzer behavior.

6.3.d Setup -> Factory -> Configuration

Device configuration for gas families and output types.

6.3.e Setup -> Factory -> Settings

Steps to access the configuration settings menu.

6.3.e.1 Minimum Visible Stain

Details the Minimum Visible Stain (MVS) feature and its settings.

CL96 Configuration Settings

Lists various configuration options including Flow Fault Filter and MVS.

6.3.e.2 Dual Pump Option

Explains the optional dual pump feature for reduced transport time and backup.

6.3.e.3 Parallel Sampling

Describes the option to share sample lines between analyzers.

6.3.e.4 Reference Validation Fault

Details features for handling reference validation errors.

6.3.f Setup -> Factory -> Restore

Procedure for restoring system settings from a backup.

6.3.g Setup -> Factory -> Update

Section for updating system software.

Chapter 7 Maintenance and Disposal

7.1 Returning to a Safe State (Post-Service)

Checks to perform before returning the CL96 to service.

7.2 Maintenance Door Access

Describes accessing the maintenance door for cassette servicing.

7.3 Control Panel Door

Instructions for opening and closing the control panel door.

7.5 ChemLogic Cassette Installation

Step-by-step guide for installing the ChemLogic cassette tape.

7.6 End of line particular filters

Details the required filters and their replacement intervals.

7.8 USB Storage Drive Replacement

Steps for replacing the USB flash drive.

7.6 Fuse Replacement

Information on replacing the system's fuse.

Chapter 8 Service & Support

Phone Support

Contact details for phone support.

E-mail us at:

Email address for support.

Appendix A Parts & Accessories

Filters & Tubing

Lists part numbers for filters and tubing.

Options and Accessories

Lists part numbers for optional equipment and accessories.

Appendix B I;O Connection Detail

B.1 EK1101 Coupler

Details the EK1101 coupler and its power sources.

B.2 Standard Output Module (24 V Sinking)

Explains the standard output module and its connections.

B.3 Optional Output Relays

Details the wiring for optional output relays.

B.4 Optional 4-20 Outputs

Describes wiring for optional 4-20mA outputs.

Appendix C System Specifications

CL96 System Specification

Lists physical dimensions, weight, power, and IP rating.

Appendix D System Event Message

COLOR CODING

Explains the color coding for system event messages.

Appendix E LDL List

Name

List of gases with their properties like TLV, LDL, and calibration PN.

Name

Continues the list of gases with their properties.

Name

Continues the list of gases with their properties.

Appendix F Hard Wire Connection (Optional)

Appendix G Optional Secondary Enclosures

G.1 Mounting A Secondary Enclosure

Information on mounting secondary enclosures.

G.1.1 Remote Secondary Enclosure Mounting

Details on mounting enclosures remotely.

G.1.2 Direct mounting on the CL96

Explains direct mounting options on the CL96 cabinet.

G.2 Connecting A;C Power to the Secondary Enclosure

Instructions for connecting A/C power to secondary enclosures.

G.2.1 Installing the liquid tight cord grip (DOD Part #2-9400-523)

Steps for installing the liquid tight cord grip.

G.2.2 Installing the A;C Power Cable

Steps for installing the A/C power cable.

G.2.3 Attaching the A;C Power inside the cabinet

Instructions for connecting A/C power inside the cabinet.

G.3 Connecting to the CL96

How to connect secondary enclosures to the CL96.

G.3.1 Connecting to the CL96 with Ethernet Cable

Steps for connecting via Ethernet cable.

G.4 Wiring Output Modules

Overview of wiring for output modules.

G.4.1 Analog (4-20 ma) Output Wiring

Refers to Appendix B.4 for analog output wiring.

G.4.2 Beckhoff Form A Relays

Refers to Appendix B.3 for Beckhoff relay wiring.

G.4.3 Form C Relay Wiring

Describes Form C relay modules and their labeling.

Appendix H Data Communication

H.1 - Ethernet;IP

Introduction to Ethernet/IP communication.

H.1.1 Data Format

Details the data mapping for Ethernet/IP communication.

H.2 - Profibus

Information on Profibus/Slave interface data availability.

H.2.1 Data Format

Details the data format for Profibus communication.

Appendix I Unified Exhaust Option Installation

Installation instructions

Lists required tools for installing the unified exhaust manifold.

3. Exhaust Manifold mounting holes

Instructions for drilling mounting holes for the exhaust manifold.

4. Installation of Exhaust Manifold.

Steps for installing the exhaust manifold.

4.4. Re-install rear panel.

Instructions to re-install the rear panel.

Summary

Chapter 1 Overview

1.1 Introduction

Overview of the CL96 system's monitoring capabilities and technology.

1.2 Theory of Operation

Explains how the CL96 detects gases using optical detection and color change on tape.

1.3 Sampling and Monitoring

Details how the system draws and analyzes sample flow from multiple points.

1.4 Electrical Connections

Mentions knockout panels for external electrical connections on the right side.

Chapter 2 Features

2.1 External Layout & Dimensions

Provides an overview of the CL96's external components and physical dimensions.

2.1.3 Touch Screen Display

Details the 19-inch color LCD touch panel for operation.

2.1.4 Keyed Service Door Access

Explains the keyed lock for restricting internal access.

2.1.8 Maintenance Door

Describes easy access for tape installation and replacement.

2.1.10 Tubing Connections

Explains the quick connection system for sample and exhaust tubing.

2.2 Maintenance Area

Describes access to the maintenance area for tape changing.

2.3 Internal Layout - Service Area

Details internal access via a keyed handle on the front panel.

2.4 Password Security

Explains password protection for accessing features.

2.5 USB Storage

Describes the use of USB drives for storing historical data.

Chapter 3 Installation

3.1 Selecting a Location

Lists conditions and restrictions for choosing an installation location.

3.2 Unloading; Loading & Installation

Provides guidance on safely moving and installing the CL96 unit.

3.3 Sample Tubing

Details sample tubing specifications and connection.

3.3.1 End-of-Line Particulate Filters

Emphasizes the requirement for filters to prevent unit damage.

3.5 A;C Power

Outlines requirements for A/C power connection.

3.6.1 Standard Output Wiring

Details wiring procedures for spring-loaded output connectors.

Chapter 4 Setup & Configuration

4.2 Gas Selection

Describes setting up each point for the appropriate gas.

4.3 Alarm Settings

Information on adjusting alarm settings for selected gases.

4.5 Concentration Logging

Details the three levels of concentration logging.

4.7 USB Storage

Explains the importance and use of USB storage drives.

Chapter 5 General Machine Operation

5.1 Introduction

Overview of touch screen operation and continuous monitoring.

5.2 General Screen Navigation

Explains the main menu and touchscreen interface navigation.

5.3 Initialization

Describes the power-on initialization sequence and auto-analysis.

Chapter 6 The Main Menu

6.1 Main Menu

Explains how the main menu allows start/stop analysis and information access.

6.1.a Analysis

Details how to start the CL96 analysis for active points.

6.1.a.2 Point Trend Detail

Shows how to view detailed information and trends for a selected point.

6.1.b Load Tape

Explains the Load Tape screen for managing cassette tapes.

6.1.c Faults;Events

Describes the Faults/Events screen for viewing recent events.

6.1.d History

Provides access to historical data stored on the USB drive.

6.1.d.1 History -> Concentration Log

Displays recorded concentrations for each point by date.

6.1.d.2 History -> Faults;Events

Shows events that occurred on a specific selected date.

6.1.d.3 History -> TWA

Displays Time-Weighted Average data, selectable by date.

6.1.d.4 History -> Storage

Shows CL96 logging capacity and USB storage drive status.

6.1.d.5 History -> Transfer

Explains transferring historical data to another USB storage disk.

6.1.e. Help

Directs to screens with useful references and information.

6.1.e.1 Help -> Manual

Introduces the interactive CL96 User Manual and PDF access.

6.1.e.2 Help -> Diagrams

Links to technical diagrams for various system components.

6.1.e.3 Help -> Contact DOD

Provides contact information for sales, support, and service.

6.1.e.4 Help -> Configuration

Displays configuration details for Analyzers A, B, and C.

6.1.f Setup

Instructions on how to enter the Setup menu.

6.2 Setup Sub-Menu

Introduces the password-protected configuration menu.

6.2.a Setup -> Point Setup

Screen for configuring individual points on each analyzer.

6.2.b Setup -Adjust Flow

Explains how to adjust pump flow rates for analyzers.

6.2.c.1 Setup -> Outputs -> Alarms

Details how to test and configure output alarms for analyzers.

6.2.c.2 Setup -> Outputs -> Point Alarms

Allows testing and toggling of point alarm outputs.

6.2.c.3 Setup -> Outputs -> 4-20 mA

Configuration screen for 0-20mA analog output calibration.

6.2.c.5 Setup -> Outputs -> Optic Test

Describes the optical strip point alarm test procedure.

6.2.d Setup -> Configure

Main screen for configuring logging and system settings.

Output Contact

Configuration of relay states (energized/de-energized) and fault latching.

Flow Fault Filter

Setting to filter flow faults based on duration.

6.2.e Setup -> Date Time

Interface for setting the system's date and time.

6.2.f Setup-> Passwords

Entry screen for passwords to access settings.

6.3 Factory Setup Sub-Menu

Introduces the factory setup menu for configuration.

6.3.a Setup -> Factory -> System

System configuration options for analyzers, communications, and offsets.

6.3.b Setup -> Factory -> Multi Pt

Configuration for enabling/disabling points across multiple analyzers.

6.3.c Setup -> Factory -> Simulation

Settings for simulating analyzer behavior.

6.3.d Setup -> Factory -> Configuration

Device configuration for gas families and output types.

6.3.e Setup -> Factory -> Settings

Steps to access the configuration settings menu.

6.3.e.1 Minimum Visible Stain

Details the Minimum Visible Stain (MVS) feature and its settings.

CL96 Configuration Settings

Lists various configuration options including Flow Fault Filter and MVS.

6.3.e.2 Dual Pump Option

Explains the optional dual pump feature for reduced transport time and backup.

6.3.e.3 Parallel Sampling

Describes the option to share sample lines between analyzers.

6.3.e.4 Reference Validation Fault

Details features for handling reference validation errors.

6.3.f Setup -> Factory -> Restore

Procedure for restoring system settings from a backup.

6.3.g Setup -> Factory -> Update

Section for updating system software.

Chapter 7 Maintenance and Disposal

7.1 Returning to a Safe State (Post-Service)

Checks to perform before returning the CL96 to service.

7.2 Maintenance Door Access

Describes accessing the maintenance door for cassette servicing.

7.3 Control Panel Door

Instructions for opening and closing the control panel door.

7.5 ChemLogic Cassette Installation

Step-by-step guide for installing the ChemLogic cassette tape.

7.6 End of line particular filters

Details the required filters and their replacement intervals.

7.8 USB Storage Drive Replacement

Steps for replacing the USB flash drive.

7.6 Fuse Replacement

Information on replacing the system's fuse.

Chapter 8 Service & Support

Phone Support

Contact details for phone support.

E-mail us at:

Email address for support.

Appendix A Parts & Accessories

Filters & Tubing

Lists part numbers for filters and tubing.

Options and Accessories

Lists part numbers for optional equipment and accessories.

Appendix B I;O Connection Detail

B.1 EK1101 Coupler

Details the EK1101 coupler and its power sources.

B.2 Standard Output Module (24 V Sinking)

Explains the standard output module and its connections.

B.3 Optional Output Relays

Details the wiring for optional output relays.

B.4 Optional 4-20 Outputs

Describes wiring for optional 4-20mA outputs.

Appendix C System Specifications

CL96 System Specification

Lists physical dimensions, weight, power, and IP rating.

Appendix D System Event Message

COLOR CODING

Explains the color coding for system event messages.

Appendix E LDL List

Name

List of gases with their properties like TLV, LDL, and calibration PN.

Name

Continues the list of gases with their properties.

Name

Continues the list of gases with their properties.

Appendix F Hard Wire Connection (Optional)

Appendix G Optional Secondary Enclosures

G.1 Mounting A Secondary Enclosure

Information on mounting secondary enclosures.

G.1.1 Remote Secondary Enclosure Mounting

Details on mounting enclosures remotely.

G.1.2 Direct mounting on the CL96

Explains direct mounting options on the CL96 cabinet.

G.2 Connecting A;C Power to the Secondary Enclosure

Instructions for connecting A/C power to secondary enclosures.

G.2.1 Installing the liquid tight cord grip (DOD Part #2-9400-523)

Steps for installing the liquid tight cord grip.

G.2.2 Installing the A;C Power Cable

Steps for installing the A/C power cable.

G.2.3 Attaching the A;C Power inside the cabinet

Instructions for connecting A/C power inside the cabinet.

G.3 Connecting to the CL96

How to connect secondary enclosures to the CL96.

G.3.1 Connecting to the CL96 with Ethernet Cable

Steps for connecting via Ethernet cable.

G.4 Wiring Output Modules

Overview of wiring for output modules.

G.4.1 Analog (4-20 ma) Output Wiring

Refers to Appendix B.4 for analog output wiring.

G.4.2 Beckhoff Form A Relays

Refers to Appendix B.3 for Beckhoff relay wiring.

G.4.3 Form C Relay Wiring

Describes Form C relay modules and their labeling.

Appendix H Data Communication

H.1 - Ethernet;IP

Introduction to Ethernet/IP communication.

H.1.1 Data Format

Details the data mapping for Ethernet/IP communication.

H.2 - Profibus

Information on Profibus/Slave interface data availability.

H.2.1 Data Format

Details the data format for Profibus communication.

Appendix I Unified Exhaust Option Installation

Installation instructions

Lists required tools for installing the unified exhaust manifold.

3. Exhaust Manifold mounting holes

Instructions for drilling mounting holes for the exhaust manifold.

4. Installation of Exhaust Manifold.

Steps for installing the exhaust manifold.

4.4. Re-install rear panel.

Instructions to re-install the rear panel.

DOD Technologies ChemLogic CL96 Specifications

General IconGeneral
Sensor TypeElectrochemical
Data LoggingStandard
Communication4-20mA output, Modbus RTU
DisplayLCD
CertificationsCE
Operating Temperature0°C to 40°C (32°F to 104°F)
Operating Humidity15% to 90% RH, non-condensing
Power Supply12-24 VDC
Battery LifeOptional battery backup for 30 minutes
Dimensions14” H x 12” W x 6” D (35.6 cm x 30.5 cm x 15.2 cm)
Weight12 lbs (5.4 kg)