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PT.

KOROSI SPECINDO
Corrosion Monitoring System Eng. Doc. No.: KS-MNL-10

Users Manual

Fixed Corrosion Data Logger


Model: DCI-DX-LPR-01
Single Channel

Revision Date Prepared Approved Description


0 17/Jul/1007 ES JH Issued for approval
1 01/Oct/2007 ES YS Issued for approval
2 07/Jul/2009 SD YS IEC clarification
3 07/Dec/2009 SD YS Add Dwg for Mounting

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CONTENTS

No Contents REV.3
1 Safety Instruction 3

2 Introduction 4
2.1 Overview 4
2.2 Equipment List 5
2.3 Variant 5
2.4 Enclosure 5

3 Instrument Installation 6
3.1 Preparation 6
3.2 Equipments or Special Tools Requirement 6
3.3 Battery Pack Installation 6
3.4 Mounting 8
3.5 Instrument Connection 8

4 Setup and Operation 9


4.1 Taking Measurement 9
4.2 Deleting Files 9
4.3 Setting Parameter 10
4.4 Downloading 13
4.5 Maintenance 14

5 Firmware 14

Appendix 1 Technical Catalog 15


Appendix 2 Probe Code 20
Note 1, Note 2, Note 3
ER Probe Guide 24

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1. Safety Instruction

The following Safety Standard should be followed in the field


a. Safe operation requires 1-trained operator.
b. Make sure you have complied with all plant safety requirements and
environmental regulations procedure.
c. Ensure you have all the required safety equipment, i.e.: protective clothing,
safety helmet, safety glasses, safety gloves, ear plug, safety shoes and
breathing apparatus when toxic atmosphere exists.
d. Test and check should be done to all equipment before attempting to use in
the field.

Importance Safeguards

All safety instructions must be read carefully & understood, before attempting to
use any KS Product (instrument, probe, equipment). This manual contains the
safety instructions that must be observed in order to avoid potential hazards that
could result in personal injuries or could damage your (instrument, probe,
equipment). This safety instruction has been classified according to the
seriousness of the risk, as follows and all identified risks categorized accordingly.

DANGER indicates the existence of a hazard that


DANGER could result in death or serious bodily injury, if the safety
instruction is not observed

WARNING indicates the existence of a hazard that


WARNING could result in bodily injury if the safety instruction is not
observed

CAUTION indicates the existence of a hazard that


CAUTION could result in property damage if the safety instruction
is not observed

Notice contains general information that relates to the


Notice safe operation of the equipment

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2. Introduction

2.1 Overview
DCI-Dx-ER-01 unit is a single channel Fixed Data Logger for field mounting
that will record corrosion activities. This corrosion monitoring instrument is
easy to operate, and has a rugged construction.

DCI-Dx-ER-01 employs the principle of electrical resistance to determine


the average corrosion rate of a metal specimen immersed in an
experimental or process stream. Examples of industries where such
process streams found are chemical plants, refineries, gas plants, oil and
gas production systems, paper mills, power plants, and tank farms.

DCI-Dx-ER-01 microcontroller electronic circuit is powered by battery pack


which it is mounted in an intrinsically safe (IP66) and housed in a NEMA 4X
rated explosion-proof, making it suitable to be applied in extreme outdoor
conditions.

It has capability to store data up to 4000 readings by battery back-up for


later retrieval.

RS-232 serial communication is provided to download data without


removing DCI-Dx-ER-01 or memory from hazardous area and setting up
the parameter such as Tag number, probe type, Probe code and reading
interval using a handheld up/downloader Model KSHHU-ER.

Monitoring temperature against corrosion rates is an important aspect to


understand the effects of temperature on corrosion. DCI-Dx-ER-01 has the
special ability to measure data temperature using a dedicated ERTemp
probe.

Fig1. DCI Dx ER 01

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2.2 Equipment List
DCI Dx ER 01 (Single Channel Fixed Data Logger)
Carrying Case
Battery Pack
Cable Communication and Connector
Operating Manual
Test Probe

Upon receipt of the instrument, the user should verify that the above listed
accessories are included.

Any shortage should be reported immediately to:


E-mail : sales@korosispecindo.com or
korosi_specindo@yahoo.com
Http : //www.korosispecindo.com
KOROSI SPECINDO
Jl. P. Jayakarta No.76, Jakarta 10730. Indonesia
Phone: 62-21 6267576 (Hunting)
Fax: 62-21 6289919

2.3 Variant
There are four variants to the product, mainly:
DCI-Dx-ER-01 Single Channel ER Sensor Measurement.
DCI-Dx-ER-04 Four Channel ER Sensor Measurement.
DCI-Dx-LPR-01 Single LPR Sensor Measurement.
DCI-Dx-LPR-04 Four Channel LPR Sensor Measurement.

2.4 Enclosure
The unit has hinges on the left side and latch in every right corner of
enclosure for securitys matters. DCI-Tx-ER equipped with safety
certification (IEC: II 1 / 2 G EEx ia IIC T4) for hazardous area operation and
housed in a NEMA 4X rated explosion-proof and weather-proof enclosure.
The probe cable is connected through a water-tight cable gland, making it
suitable to be applied in some outdoor conditions.
Overall dimensions are 152 mm (height), 152 mm (width), 102 mm (depth),
making it a convenient size to mount even in the most restricted location.

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3. Instrument Installation

The Data Logger operates on a ratio metric measurement principle, whereas


such measurements are made on exposed sample element of the probe subject
to corrosion or erosion and a protected reference element inside the probe body.
The recorded reading is a ratio of Rs/Rr. The Data Logger records every minute
of changes in the probe resistance at set intervals and stores them in the
memory which may be down-loaded to KSHHU-ER via RS-232 communication
serial in a hazardous area.

The Data Logger also records the Ratios of Rc/Rr, which are used to check the
probe performance under operating conditions. A constant CHECK reading
indicates that probe internals have not been subjected to corrosion.

3.1 Preparation
1. Safety Procedure always ask for a person who will be in charged in
the field, specifically an Instrument, or Electrical, or Corrosion
Engineer who will take responsibility in the field during Installation of
DCI-Dx-ER-01 and other accessories.
2. If you plan to protect the wiring between the Corrosion Probe and the
DCI-Dx-ER-01 or any related Instrumentation using Conduit for the
first time or during your field survey, always prepare Sketch Drawing
or Draft on the notebook of every length, position, and angle of
direction. Make sure that the conduit accessories to be as efficient as
possible, and be located closest to existing cable tray on that level and
location.
3. During wiring process, do not cut any cable in a hazardous area if you
are not sure enough that the correct lengths of all cable for
Instrumentation are screened (armored) in overall length. So, you
should not extent or make any connection without Junction Box,
except in Non Hazardous area.
Any extension or connection between two cables will result in
unwanted noise affecting the sensitivity of the signal and resulting in
erroneous data or malfunctioning of the monitoring system.
4. Always Test all of your Equipment before you attempt to installed this
in the field. Prepare any tools such as, spare ER probe, extension
probe, Probe Cable, Dummy Probe, Battery Pack etc.
5. Bring all Documentation and Manual Book along to the field for
conducting Installation, setting parameter and Troubleshooting.

Note: Operator must concern to Local Safety Requirement, the safety


requirements according to described in operating and maintenance
manual of equipment, the requirements of the relating explosion proof
standards as well as the requirements and instructions of MSZ EN
60079-10:2003, MSZ EN 60079-14:2003, MSZ EN 60079-17:2003
standard.

3.2 Equipments or Special Tools Requirement


Test Probe.
Crow Spanner to open or to tighten the probe connector.
Analog/Digital Multi-meter, soldering iron and electronic tools set.

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3.3 Battery Pack Installation
The DCI-Dx-ER-01 is supplied with battery pack as primary power and
installed inside the main housing. It is easy to install this battery pack,
which is by removing the two metal hinges on the right corner up and to the
right corner down of the front enclosure, then by connecting the battery to
the electronics box.
Hinge

Battery Pack

Electronic box

Male Connection

Probe Cable

Battery Pack

Hinge

Fig. 2 Battery Pack installation

Battery Pa ck Capacit y (mA)


Life Time
Measuremen t Current (mA) X Mea surement T ime ( min s) Standby

Re ading Inte rval ( min s) Current (mA)
Battery Pack Capacity : 1900 mA
Measurement Current : 50 mA
Measurement Time : 50 second
Reading Interval : 1 minutes to 1 hour
Standby Current : 15 mA

Setting up the reading at long interval or short interval can affect the battery
lifespan.

Note: General safety recommendations for Lithium Batteries have been


published in the standards UL 1642 and IEC 60086-4

WARNING: Fire, explosion, and severe burn hazard. Do not recharge, disassemble,
heat above 100C, incinerate, or expose contents to water.

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3.4 Mounting
DCI-Dx-ER-01 is mounted in field and can be covered by an optional
Environment Protection Box (EPB) to protect from environment
disturbances such as sunlight, rain, wind or sea breeze. Environment
Protection Box (EPB) made from Aluminum, for the application in harsh
climates Enclosure NEMA 4X and IP66 is standard.
Environment Protection Box (EPB) should be earth grounded.

Fig.3. Environment Protection Box (EPB)

Yoke mounting can be order separately, which customer able to install DCI
Box directly in the field pipe mounting both horizontal or vertical position.

Fig.4. Yoke Mounting.

3.5. Instrument Connection

Probe DCI-DX-ER-01
Fixed Data Logger must be installed at appropriate location and connected
at probe lead to the ER probe. Extension adapter is required to have
connection between ER probe and the instrument. Probe Cable length
standard is 10 feet (3 meters, other length 8 or 10 meters is optional)

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Fig.4. Connection between Probe and DCI-DX-ER-01

Fig.5. Connection between DCI-DX-ER-01 and KSHHU-ER

Remove protective cap on the connector when downloading and setting


up the parameter. Connect the cable of RS-232 communication serial
between the five pins serial port connector on the DCI-Dx-ER-01 and the
nine pin serial port D-connector on the KSHHU-ER.

Parameters can be pre-set or programmed depends on customers need


in the hazardous area i.e. measurement interval, Tag number, probe
type, etc.

Note: down load all existing record data, before change preset Logger to new
parameter; for example: change measurement interval, tag number,
probe type, etc. from previous preset.

4. Setup and Operation.


Soon after installed the battery pack, the instrument will be ready to operate. This
instrument is furnished without display and keypad, so to configure the parameter,
to transfer data and to delete files please might use KSHHU-ER.

4.1 Taking Measurement

It will automatically read the probe depending on customer-selected intervals


and store results of reading in the memory.

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4.2. Setting Parameter DCI

KSHHU is designed to up/down-load data and set DCI parameter. Time and
date on DCI will be automatically applied after synchronizing with KSHHU.
The following will explain parameter setting procedures of a DCI using
KSHHU.

Note: For erosion probe can use flush probe type where metal loss as
graphic represents erosion in mils.

Connect KSHHU to DCI using DCI Cable Connection, turn on KSHHU and
press ENTER from standby menu to go to main menu display:

(1) SET DCI (5) UPLOAD


(2) MEMORY (6) READING
(3) SET TIME
(4) DOWNLOAD
Press 1 (SET DCI) from main menu to go to select probe type display:

SELECT PROBE TYPE


> TUBULAR 10 <

<< PREV NEXT>>

Press right arrow (NEXT) and left arrow (PREV) to select probe type and
thickness that will use DCI on field; . e.g.: Tubular 10, 20, 40, 50, 80; Tube loop
04, 08; Wire loop 40, 80; Flash10, 20, 40. etc.

Then press ENTER key and the display shall continue to:

WRITE TAG NUMBER

> <

Tag Number can be written in both alphabetic and numeric. Insert maximum ten
digits tag number then press ENTER key to go to the read interval display:

WRITE READ INTERVAL


HHMM
> <

Note: Maximum Value for read interval is 2400, Minimum value for read Interval
is 0001
HH for Hour and MM for Minutes

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Press ENTER to go to confirmation display:

WRITE READ INTERVAL


HHMM
> 2400 <
(1) SEND (2) ABORT

Press (2) to abort process and return to previous display.


Press (1) to continue process and LCD will display:

SENDING
.

Note:
XX is a Shown that Process is running.
Check cable to make sure that cable is connected between DCI and
KSHHU.

If any trouble due to connection or low battery capacity in DCI, a warning display
will be shown as below:

CABLE NOT CONNECTED

After correction has been done and battery has been charge, after a moment
screen will display:

COMPLETED

(PRESS ENTER)

DCI has been set up, press ENTER key to go to main menu display and unplug
cable connection.

Press ENTER to go to confirmation display:

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WRITE READ INTERVAL
HHMM
> 2400 <
(1) SEND (2) ABORT

Note: HH for Hour and MM for Minutes.

Press (2) to abort process and return to previous display.


Press (1) to continue process at which time the LCD will display:

SENDING

Note: Check cable to make sure that cable is connected between DCI and
KSHHU. If cable is not connected, a warning display is shown below:

CABLE NOT CONNECTED

Wait for a couple of seconds after which press 1 (SEND) and the screen will
display:

COMPLETED

(PRESS ENTER)

DCI has been set up, press ENTER key and unplug cable connection to go to
main menu display.

4.3. Download Data from DCI

Connect KSHHU to DCI with a RS-232 serial cable communication (supplied


cable), powers on KSHHU then press ENTER from standby menu and display
will show main menu:

(1) SET DCI (5) UPLOAD


(2) MEMORY (6) READING
(3) SET TIME
(4) DOWNLOAD

Press 4 (DOWNLOAD) from main menu display and downloading of data will
immediately be showed as follow:

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DOWNLOADING
XXXX/XXXX

Note:
XX % is a shown that process is running
Check cable to make sure that cable is connected between DCI and
KSHHU. If any trouble either in connection or low battery capacity in DCI,
a warning display is shown below:

CABLE NOT CONNECTED

After both connection and battery capacity in DCI has been solve, wait for few
moment to complete the download process and the screen will display:

COMPLETED

When process is completed, all data has been stored in KSHHU memory. Press
ANY KEY to go to main menu display and unplug cable connection.

4.4. Maintenance

4.4.1. Ensure that the probe is operational and is not completely corroded.
4.4.2. Examine all electrical connection for proper electrical connections, check
sign of corrosion to ensure that the connections are environmentally
protected.
4.4.3. Contact Korosi Specindo for technical assistance if the Data Logger
continues to malfunction.

Note: Operator must concern to Local Safety Requirement, the safety


requirements according to described in operating and maintenance
manual of equipment, the requirements of the relating explosion proof
standards as well as the requirements and instructions of MSZ EN
60079-10:2003, MSZ EN 60079-14:2003, MSZ EN 60079-17:2003
standard.

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5. Firmware

DCI-DX-ER is a micro controller based unit and all its functions are firmware
controlled. These functions are accessed by issuing appropriate commands as
per the command set.

To establish communication with the data logger and instruct it to perform the
actions of an individual command, HyperTerminal is used via serial RS-232
(lower left side 6 pins connector).

The Data logger functions can be programmed and the data up loaded to PC via
the portable handheld unit model KSHHU. HyperTerminal is the most efficient
way to communicate with the Data Logger. Analyze the corrosion data using KS-
Corrosion Monitoring Software which is provided with the DCI and KSHHU unit.

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Appendix.1.Technical Catalog

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Appendix 3.

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