DCL Exhaust Monitor-Logger Manual September 2018

INSTALLATION, OPERATION & MAINTENANCE
MANUAL
P.O. Box 90, Concord, Ontario, Canada L4K 1B2
Toll Free: 1-800-872-1968 Fax: 905-660-6435 Email: info@dcl-inc.com

DCL EXHAUST MONITOR/LOGGER 1/28
www.dcl-inc.com
INSTALLATION OPERATION AND MAINTENANCE MANUAL
LAST REVISED: OCTOBER 2010 X0001-0000-65
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DCL EXHAUST MONITOR/LOGGER
Table of Contents
1 GENERAL SYSTEM DESCRIPTION ....................................................................................................................................... 1
1.1 Logger Basics........................................................................................................................................................................... 1

1.2 Memory..................................................................................................................................................................................... 1
1.2.a Memory for Measured Values .............................................................................................................................................. 1
1.2.b Memory for the Alarm Function .......................................................................................................................................... 1
1.3 Download Kit & Software (Optional).................................................................................................................................. 2
1.4 Special Programs ..................................................................................................................................................................... 2
2 COMPONENTS ............................................................................................................................................................................... 3
3 INSTALLATION.............................................................................................................................................................................. 6
3.1 Mounting the Control Box ..................................................................................................................................................... 6

3.2 Making the Backpressure Connections ............................................................................................................................... 6
3.3 Making the Temperature Sensor Connections.................................................................................................................... 7
3.4 Mounting the Display ............................................................................................................................................................. 7
3.5 Making the Cable Harness Connections.............................................................................................................................. 7
4 OPERATION .................................................................................................................................................................................... 9
4.1 Pressure Monitor Display....................................................................................................................................................... 9

4.2 Troubleshooting .....................................................................................................................................................................10
4.2.a Error Code 1: Upper Pressure Limit Alarm .....................................................................................................................10
4.2.b Error Code 7: Time & Date ................................................................................................................................................11
5 MAINTENANCE ...........................................................................................................................................................................12
6 DOWNLOAD KIT & SOFTWARE (OPTIONAL).................................................................................................................13
6.1 Software Installation Instructions ........................................................................................................................................14

6.2 Making the Connections .......................................................................................................................................................15
6.3 Performing a Download ........................................................................................................................................................15
6.4 Retrieving Downloaded Data ...............................................................................................................................................17
6.5 Software Capabilities.............................................................................................................................................................18
6.5.a Temperature Trace, Histogram and Online Data ..............................................................................................................18
6.6 Time Out Error .......................................................................................................................................................................19
7 ADD-ON DEVICES (OPTIONAL) ...........................................................................................................................................22
8 DCL EXHAUST MONITOR/LOGGER ELECTRICAL DIAGRAM ....................................................................................23
APPENDIX A ............................................................................................................................................................................................24
APPENDIX B ............................................................................................................................................................................................25
1 GENERAL SYSTEM DESCRIPTION
1.1 Logger Basics
The DCL Exhaust Monitor/Logger is a system for monitoring the status of the MINE-X SOOTFILTER®
Diesel Particulate Filter (DPF), MINE-X Catalytic Converter or MINE-X Flow-Through Filter (FTF).
Exhaust gas backpressure and temperature readings are taken continuously, and an alarm panel mounted
in the operator’s cabin visually informs the operator of operating exhaust gas backpressure and
temperature, and also provides important information regarding any errors that occur with the DPF,
Catalytic Converter or FTF system via a problem codes indicator.
The logging feature of the system allows for analysis of operating history should this be required. Also
available with this system is an optional add-on GSM/GPRS unit which provides the ability to monitor
the status of the system remotely, and an optional CAN bus system which can output logger info to a
remote location.
DCL requires that a working exhaust monitoring system be installed with every MINE-X SOOTFILTER®
DPF.
1.2 Memory
The Exhaust Monitor/Logger has two separate memories:
1.2.a Memory for Measured Values
Pressure and temperature are continuously measured at 1 second intervals; 10 second mean values
are computed and these are stored in the memory together with the corresponding date and time.
The storage capacity of the circular memory is sufficient for roughly 360 days (24 hours/day) of
operation when recording two external input channels (pressure and temperature).
Once the logger memory is saturated, the circular memory system begins to overwrite the oldest
stored data. This is a continuous process.
1.2.b Memory for the Alarm Function
The purpose of the alarm function is to report various system problems such as: high or low
backpressure events, a break in the connection to the temperature probe, etc. As well, alterations to
settings made in the control box setup are registered in this secondary memory. Each entry is stored
together with a record of the relevant time and date, and commentary. The non-volatile circular
memory is designed for a service period of 10 years, and can store up to 20,000 data records.

LAST REVISED: SEPTEMBER 2018 X0001-0000-65
1.3 Download Kit & Software (Optional)
The optional download kit and software provides the ability to download the operating history of the
exhaust temperature and backpressure for analysis/evaluation. The software provides an easy to use
interface to review the collected data and alarm history log. See Section 6 for detailed information on the
download kit and software.
1.4 Special Programs
If more sophisticated functions are required than those described in this manual (i.e. secondary alarm
outputs, dosing control requirements, etc.) please contact DCL Technical Support at 1-800-872-1968 for
assistance.

2 COMPONENTS
Below, Table 2.1 lists the individual components of the DCL Exhaust Monitor/Logger, DCL
Remote Monitoring System (Optional) and the DCL Download Kit (Optional).
Table 2.1 – Components List

DCL Exhaust Monitor/Logger (System Part Number: X0800-0036-00)
Item Description Component Part Number Quantity
Control Box X0800-0036-01 1
Off-Road Cable Harness (inc. Thermocouple) X0800-0036-02 1
Off-Road Pressure Monitor Display (IP67) X0800-0036-04 1
Stainless Steel 1/4" Connector X0800-0036-05 2
Stainless Steel Tubing (~20") X0800-0036-06 1
High Temperature Resistant Hose (~6ft) X0800-0036-07 1
Fuse X0800-0036-08 1
Display Face Mounting Bracket X0800-0036-12 1
Condensate Trap X0800-0036-15 1
1/4" NPT - Hose Fitting X0800-0036-19 2
Ring Clamp X0800-0036-26 2
Threaded Screw X0800-0036-27 2
DCL Remote Monitoring (System Part Number: X0800-0035-00)
GSM/GPRS Module X0800-0035-02 1
Cable Harness X0800-0035-03 1
GSM/GPRS Antenna X0800-0035-04 1
Hub Box X0800-0035-05 1
DCL Download Kit (System Part Number: X0800-0034-00)
USB Serial Converter X0800-0034-01 1
Network Cable - 2" X0800-0034-02 1
USB Extension Cable X0800-0034-03 1
DCL Exhaust Monitor/Logger Software X0800-0034-04 1
Converter (Ethernet - Female Deutsch) X0800-0034-05 1

CONTROL BOX (X0800-0036-01)
To be installed in the engine compartment. The control box
contains the logic for the system. It has a connection for the cable
harness and a connection for the pressure hose. A mounting bracket
is also secured to the back of the unit for installation purposes. The
control box is rated IP63 for dust and water penetration, and has an
operating temperature of -20°C to 80°C.
PRESSURE CONNECTIONS:
High Temperature Resistant Hose (X0800-0036-07)
Stainless Steel Tubing (X0800-0036-06)
Stainless Steel 1/4” Connector (X0800-0036-05)
Provides pressure line connections between the exhaust system and
the control box. The pressure connection set includes a stainless
steel connector, stainless steel tubing, and the high temperature
resistant hose. The high temperature resistant hose is flexible
permitting easy installation.
FUSE KIT (X0800-0036-08)

Integrated in the power-supply (permanent positive polarity);
provides protection against over-voltage. It is required that the fuse
be installed to protect the control box.

CONDENSATE TRAP (X0800-0036-15)
Must be mounted vertically in a location that will allow

moisture in the system to collect in the trap. The trap must
be installed such that the arrow on the trap points in the
direction of the exhaust flow (towards the control box).
Before installing the condensate trap, it is important to
make sure the drain valve located at the bottom of the trap
is closed by pulling down on the nozzle and twisting to the
right. See fig. 3.1
CABLE HARNESS (X0800-0036-02)

Table 2.2 – Terminal Description
A: Power Supply
C Red Battery (10-30 VDC)
D
Black/Red Ignition
For stationary applications:
A “engine on”
B Black Ground
B: Thermocouple
C: Bus to Display Panel (Male Deutsch Connector)
D: Inputs and Outputs
Contains the thermocouple, and Violet Input for rpm
provides the necessary connections Brown Vacant Input 1
between the control box and the
Blue/Yellow Vacant Input 2
power source. The cable harness
contains four main terminals, as Black/White Alarm Output 1
described in table 2.2. Black/Green Alarm Output 2
DISPLAY PANEL (X0800-0036-04)

Must be installed in view of equipment/engine operator.
The Display panel consists of 3LED bars, the alarm light,
and reset button, which are used to indicate the operating
status of the DPF.

3 INSTALLATION
3.1 Mounting the Control Box
Disconnect battery before proceeding with sections 3.1- 3.5
The control box is to be installed in a position such that it is protected from impact, excessive water and
excessive heat. Inside the engine compartment is generally the most ideal location for mounting the control
box. Installation should be done such that the connectors (backpressure hose fitting and wiring harness) are
facing downwards. It is also desired to position the control box above the exhaust system. This will prevent
condensate (from the exhaust) from being drained into the pressure sensor located in the control box. A
condensate trap (provided) must be installed regardless of whether or not the control box is installed above or
below the exhaust system.
Excessive temperatures outside of the control box operating range (-20°C to 80°C) may result in
failure of the control box. As mentioned above it is important to locate the control box such that it
will be protected from impact, excessive water and excessive heat.
3.2 Making the Backpressure Connections
1) Remove exhaust pipe components before proceeding with the following instructions (Recommended).
2) Drill a hole 3” - 6” upstream of the filter in the exhaust pipe at the 12 o’clock position.
3) Weld a ¼” NPT female port over the drilled hole making sure that exhaust gases cannot escape around
the perimeter of the weld.
4) Insert the provided stainless steel tubing through one stainless steel ¼” NPT connector and insert into
the ¼” NPT female port. Position the tubing such that it sits slightly into the exhaust stream and tighten
the connector such as to lock the stainless steel tubing in this position.
Ensure to ground while welding.
The stainless steel tubing is not to be shortened as it is used to dissipate heat from the exhaust.
For the proceeding instructions, please refer to figures 3.1-3.4 which illustrate proper and improper
backpressure line connections.
5) Determine an appropriate place to mount the condensate trap. The trap location should allow moisture in
the system to collect in the trap.
6) Mount the condensate trap using the provided screws. Ensure vertical orientation of the trap and install
such that the arrow on the trap points in the direction of the exhaust flow (towards the control box).
7) Cut the high temperature resistant hose, and connect one piece to the stainless steel tubing and secure
with a ring clamp. The other end of the high temperature resistant hose connects to a ¼” NPT hose
fitting, which connects to the condensate trap. If possible, avoid coiling the stainless steel tubing and
high temperature resistant hose. If coiling is unavoidable, ensure that the coils allow for condensate to
drain either back into the exhaust stream, or into the condensate trap.
8) Use the remaining portion of the high temperature resistant hose to connect the control box to the
condensate trap.
9) Ensure that the condensate trap is closed by pulling down on the nozzle and twisting to the right. It
should lock in position.

3.3 Making the Temperature Sensor Connections
1) Drill a hole 3” - 6” upstream of the filter in the exhaust pipe at the 12 o’clock position.
2) Weld a ¼” NPT female port over the drilled hole making sure that exhaust gases cannot escape
around the perimeter of the weld.
3) Insert the thermocouple through a stainless steel ¼” NPT connector and insert into the ¼” NPT
female port. Position the thermocouple such that the tip is approximately in the middle of the
exhaust tubing and tighten the connector to lock the thermocouple in this position.
4) Be sure not to secure the thermocouple wire to any components that may become hot during
operation.
5) Reinstall the exhaust pipe components.
Ensure to ground while welding.
3.4 Mounting the Display
An optional display panel mounting bracket is included with the exhaust monitor/logger kit. The display
panel should be mounted such that it is visible to the machine/engine operator, and such that the deutsch
connection located behind the display is accessible. It is safe to mount the display outdoors as the unit is
rated IP67 for dust and water protection.
3.5 Making the Cable Harness Connections
Connect all necessary cables from the cable harness before connecting the cable harness plug to
the interface on the control box.
Please see table 2.2 in section 2 Components for details on individual wire connections.
1) Disconnect the battery (should already be disconnected from section 3.1).

2) Install the fuse on the constant positive power wire and connect the power supply wires from coil
A.
3) Connect cable C to the display panel.
4) Connect the harness plug to the interface on the control box.
5) Tape up the ends of all wires from coil D as for normal monitor/logger use, these additional inputs
and outputs will not be needed.
6) Re-connect the battery.
If there are any questions regarding installation, please contact DCL at 1-800-872-1968.

Control Box
Stainless Steel
Tubing
High Temperature
Resistant Hose
Stainless Steel ¼”
Connector
Condensate Trap
Drain Valve
Twist to close Twist to open
Fig. 3.1 Acceptable Set-Up Set Up
Fig. 3.2 Acceptable Set Up Fig. 3.3 Acceptable Set Up Fig. 3.4 Un-Acceptable Set Up

U
4 OPERATION
4.1 Pressure Monitor Display
The DCL Exhaust Monitor/Logger display panel is shown below in Figure 4.1.
Temperature Indicator LED Bar
Pressure Indicator LED Bar
Problem Code LED Bar

Reset Sensor
Alarm Lamp
Figure 4.1 – DCL Exhaust Monitor/Logger Display Panel
Table 4.1 – Display Panel Features

Feature Description
Temperature Indicator LED Bar Provides a guide as to the relative temperature of the exhaust
system
Pressure Indicator LED Bar Provides a guide as to the relative backpressure of the exhaust
system
Problem Code LED Bar Used as a diagnostic tool to determine the root cause of a system
problem
Alarm Lamp Illuminates in order to warn the operator of a system problem
Reset Sensor Allows monitor/logger problem codes and alarms to be reset
Self-Check
Upon ignition, or, “engine on”, the monitor will proceed with a self-check during which the LEDs will go
through a sequence to determine proper functionality of the monitor. Once the self-check is complete, the
temperature and pressure indicator bars will illuminate showing current parameter status.

4.2 Troubleshooting
During operation, the alarm lamp may illuminate warning the operator that a problem has arisen with either the
DPF or the monitor/logger itself. The following troubleshooting information has been formulated to assist
installers and operators with resolving problems which may be experienced in field. For convenience table 4.2
in Appendix B lists and summarizes a number of various problem codes and corrective actions to be taken by
the operator. For more detailed information and instructions on actions to take when experiencing any of the
alarm codes listed in table 4.2, please refer to the MINE-X SOOTFILTER® Installation Operation and
Maintenance Manual.
4.2.a Error Code 1: Upper Pressure Limit Alarm
What to Look For: On the Display Monitor, problem code 1 LED

light along with the Pressure 8 indicator LED will be illuminated and the
Alarm Lamp will be flashing.
Alarm Description: Pressure inside the filter has increased to a level

above the maximum allowable safe soot load, causing excessive
backpressure. This may be a result of a build-up of soot in the filter,
caused by an engine malfunction or low duty-cycle, and/or a build-up of
ash material in the filter, usually caused by neglecting to perform a
required scheduled maintenance at every 1000 operating hours.
Instructions: If the high-pressure Alarm Lamp is triggered, reset the monitor manually by moving your finger
over the alarm Reset Sensor. This should cause the alarm to turn off. If the Alarm Lamp again illuminates
within 2 minutes after continuing with normal operation, then proceed with the following:
1) Apply high torque to the engine for a continuous period of 20 minutes at medium to high RPM*.
2) Reset the Alarm Lamp manually by moving your finger over the Reset Sensor if it has not turned off
automatically during the high torque operation.
3) If within 2 minutes of resetting the Alarm Lamp, the Alarm Lamp comes back on, remove the DPF and
perform a Level 1 Cleaning or Level 2 Cleaning (refer to the MINE-X SOOTFILTER® Installation
Operation and Maintenance Manual Section 5 Maintenance for cleaning instructions). Please contact
your local authorized MINE-X SOOTFILTER DPF cleaning facility or DCL Technical Support at 1-
800-872-1968 for assistance.
*The high exhaust temperatures generated from high torque operation will cause the DPF to self-regenerate.
Examples of how to apply high torque include driving the equipment up an incline or moving/hauling a heavy
load. Do not operate the equipment unsafely or in a manner that will cause damage to the equipment
hydraulics or other components. If uncertain of how to properly conduct this operation, please contact DCL.
If the Problem Persists: If you continue to experience the alarm after the above steps are taken, there is most
likely a problem with the engine, resulting in excess soot build-up in the DPF. Conduct an opacity test on the
machine without the DPF in place to confirm this issue and consult your equipment dealer for resolution.
Future Steps: To avoid this problem in the future, utilize the machine in applications with heavy duty-cycles
wherever possible. Keep up with all scheduled maintenances for both the DPF and engine to ensure both
continue to perform optimally and as required.

4.2.b Error Code 7: Time & Date
What to Look For: On the Display Monitor, problem code 7 LED light
will be illuminated and the Alarm Lamp will be flashing.
Alarm Description: If you experience Alarm Code 7 this means the

date and time is not set and data is not being recorded.
Instructions: To reset the date and time with your computer connected
to the control box, do the following
1) Open up the MRS Terminal program.
2) Click on Parameters
A new window will open up, which contains all the parameters/default settings. Changes can be made to
the date and time by simply clicking on the ‘Set Control Box Time’ button. The current time and date set
on your laptop/PC will be transferred to the control box. Therefore it is important to ensure that your
laptop/PC is displaying the correct time and date. See figure 4.2 below.

5 MAINTENANCE
In order to ensure that the monitor/logger is functioning properly and to extend the useful life of the
monitor/logger system, regular maintenance must be performed on the temperature sensor and the
pressure connections. Below are the maintenance requirements for these components.
Table 5.1 – Regular Maintenance Schedule

Component Frequency of Cleaning Cleaning instruction
Temperature Sensor Once a year or every  Remove the temperature probe from the exhaust
(Thermocouple) 1000 hrs of operation stream
 Using a cleaning solvent, wipe down the probe
and reinstall into the exhaust stream
Pressure Once a year or every  Remove the high temperature resistant hose
Connections 1000 hrs of operation from the control box and disconnect from the
stainless steel tubing
 Remove the stainless steel tubing from the
exhaust stream
 Rinse each component with water to remove
soot build-up within each tube
 Blow-dry both components with compressed air
 Reassemble the pressure connections
Condensate Trap/ As required  Remove condensate from trap as necessary
Moisture Separator
If there are any questions regarding maintenance procedures for the DCL Exhaust Monitor/Logger, please
contact DCL.

6 DOWNLOAD KIT & SOFTWARE (OPTIONAL)
The optional download kit and software provides the ability to download the operating history of the
exhaust temperature and backpressure for analysis/evaluation. The software provides an easy to use
interface to review the collected data and alarm history log. Table 6.1 below shows the download kit and
components.
Table 6.1 Download Kit Parts List

Carrying Case
CD for Software Installation
Converter: Ethernet -Female Deutsch

(X0800-0034-05)
Network Cable (X0800-0034-02)
USB Signal Converter (X0800-0034-01)
USB Extension (X0800-0034-03)

6.1 Software Installation Instructions
1) Do not connect the signal converter to your PC/laptop at this stage!

2) Insert the CD supplied with the download kit, and start the ‘2nd_Analyser_Setup.exe’ file. Choose
your language, press the ‘ok’ button, and follow the onscreen instructions until installation is
complete. See table 6.1 Download Kit Parts List
3) For the destination folder, use the recommended C:\ default location.
4) Open the MRS-Terminal program. If it is not in English perform the following: click on the ‘setup’
tab, followed by ‘sprache’ see figure 6.1 below. Choose English and click yes to the message that
pops up. Close and re-open the MRS-Terminal program, and the changes will be applied.
Figure 6.1 Setting Language to English

6.2 Making the Connections
1) Connect the USB signal converter into a USB port on your PC/laptop.
 Wait a few seconds to ensure the serial box has been recognized by the Windows
operating system: The first time the USB signal converter is connected, an information bubble
will appear indicating “found new hardware” followed by a second information bubble stating
the USB has been recognized. Subsequently, you will no longer see these messages.
 It is now safe to make the other connections.
Figure 6.2.a Making the Connections Figure 6.2.b New Hardware
USB Signal Converter
USB Port
2) Make sure the power is on by turning the ignition key

key. Leave the ignition on until the download is
complete. For stationary applications, make sure to have the “engine on” signal.
To test if the power is on, plug the off-road monitor display into the male deutsch plug
from the wire harness. If the power is on the display will illuminate.
Connect
Bus Cable
Figure 6.2.c Making the Connections
3) Using the supplied hardware, connect the male deutsch plug from the wire harness to the USB
signal converter. See figure 6.2.c
6.3 Performing a Download
1) Open the MRS-Terminal program on your desktop.
2) Click ‘Load Data from Control Box’. See figure 6.3.a.

 The download will begin automatically; if there is a lot of data stored in the control box, this
may take up to 20 minutes.

Figure 6.3.a: Performing a Download
 During the download, at the bottom of the screen you should see consistently changing info
which is a sign that the data from the control box is being read. Once complete, there will be a
message at the bottom of the screen which says, “Data from Control Box has been
downloaded”. The data on your control box has now been downloaded and saved as two files
on the hard disk, (a zip file and Microsoft Access file). These files are readily available for
your personal reference and review at anytime. See figure 6.3.b below:
Figure 6.3.b Download data file format
DATA_ALARM26421_111109_113532.zip
DATA26421_111109_113532.mdb
5 digit control Time: hr:min:sec

Date: dd/mm/yy
box serial number
The zip file is a compressed file password protected, and suitable for sending as an email
attachment See figure 6.4. When sending a download file to DCL for analysis, please be sure to
send the zip file.
3) Once you are finished with the MRS-Terminal program, you can end/close it and unplug the
connections. There is no particular order to unplug the connections, and the download data has
already automatically been saved.

6.4 Retrieving Downloaded Data
1) Downloaded files can be retrieved by going to: C:\CPK-Terminal\DATA
2) To review downloaded data, open MRS-Terminal and click ‘Import Control Box Data From Database’.
When the database opens, choose which file to view from the default folder. See figure 6.4.
 For capabilities of the software, please see section 6.5. Some of the software capabilities include
graphical analysis, which can be view by clicking on the ‘Data_Diagram’ tab or more specific info
by clicking on ‘Parameters’.
Figure 6.4: Retrieving Download Data

6.5 Software Capabilities
6.5.a Temperature Trace, Histogram and Online Data
Figure 6.5.a, 6.5.b and 6.5.c shown below, are three depictions of the software capabilities of the DCL Exhaust
Monitor/Logger.
Figure 6.5.a Histogram
Figure 6.5.a is a histogram of the exhaust backpressure

(blue) and the exhaust gas temperature (red). The
histogram is a visual representation of the exhaust
backpressure and temperature percentage between
specific ranges. This data can be found under the
Report tab.
Figure 6.5.b Trace

Figure 6.5.b shows a plot of the exhaust backpressure
and exhaust gas temperature of the diesel particulate
filter, over the time the system has been installed. To
view this data, click on the Data_Diagram tab.
Another key feature of the data diagram function is the
ability to remove specific data series values such as
temperature or pressure by un-checking the associated
box as shown in figure 6.5.b. Also available is the
ability to zoom in on any section of the graph by left
clicking on the mouse and dragging the mouse over a
given portion of the graph.
Figure 6.5.c Online Data

LED lights on the display panel represent the status of
the exhaust backpressure and temperature experienced
by the diesel particulate filter. To view a numeric
illustration of these parameters as well as others, the
online data function can be used. Connections must
first be made as in section 6.2. The online data
function can be found under the Online_Data tab.
Click this tab to view measured parameters in real-
time.

6.6 Time Out Error
Com-Port/Time Out errors are the most common problems one may experience in performing a download. In
such cases, the goal is to match the Com-Port number which the computer ‘sees’ (through device manager),
with the Com-Port number in MRS-Terminal from which the download software is trying to read. Once these
ports match, you are ready to perform a download. Below are step by step instructions to be performed if
experiencing any Com-Port/Time Out connection issues.
1) Check all connections.

2) Make sure ignition is on (Test this by making sure the off-road display lights up).
 For stationary applications, make sure to have to “engine on” signal.
3) Check device manager of the windows system for USB port.
(Start Control Panel System Hardware Device Manager Com-Ports) See figure 6.6.a
 In Windows XP, click on the ‘Hardware’ tab, and then click ‘Device Manager’.
 In Windows Vista, click on the ‘Device Manager’ tab.
 In Windows 7, click on the ‘System & Security’ tab, and then click ‘Device Manager’.
 Open the ‘Ports’ section by clicking on the plus (+) sign.
Unplug and then plug the USB signal converter in again, look at the ‘Com-Port Device’ section on the
screen, a new com-port named ‘USB serial port’ should appear (Note the USB serial port number as this
will be needed for step 8) See figure 6.6.a.
 If you do not see ‘USB serial port’ and the USB signal converter is plugged in, try a different
USB port on your PC/laptop.
 If you do not see ‘USB serial port’ and you are using the USB extension, try plugging in the
USB Signal Converter directly into the PC/laptop, bypassing the extension cable. If this
solves the problem, do not use the extension.
The following steps 4-6 can be done by clicking on the desktop MRS-Terminal short cut icon. If
you do not have this icon, or cannot find it please perform the following steps.
4) Click on the ‘Start’ button and select ‘All Programs’.

5) Find and click on the ‘CPK Automotive’ icon.
6) Open the ‘MRS-Terminal’ program.
7) Click on the ‘COM-connection’ properties menu item. See figure 6.6.b
8) Under settings there is a pull down menu to the right of the word ‘Port’. In the box is a COM
number see figure 6.6.b.
a. If the COM port found for the USB serial port is not the same as that listed in the device
manager, select this port from the list.
b. If the COM port needed is not in the list:
i. Attempt ‘Reinstalling the driver file’ and proceed again with “Matching the
COM Ports” – (For reinstalling the driver file see figure 6.6.c reinstalling driver).
ii. Try a different USB slot in your laptop and proceed again with “Matching the
COM Ports”.
iii. With the USB signal converter alone connected to your PC/laptop (disconnect all
other cables), try rebooting the computer and proceed again with “Matching the
COM Ports”.

9) Once the COM ports match, you should be ready to perform a download.
Figure 6.6.a Device Manager
Upon performing a download, if you receive an error message indicating: “Control Box is Not
Answering” remove the control box and inspect the inner pin connections as one may be loose or
damaged. If there is damage to the pins, please contact DCL.

Reinstalling the Driver File
1) Make sure the USB signal converter is not plugged into the laptop/PC
2) Open up ‘My Computer’
3) Go into the ‘C: Drive’
4) Go into the ‘CPK-Terminal’ folder
5) Double click on the ‘usb_inst’ file
6) A box will be displayed on the screen, and the driver has been reinstalled. See figure 6.6.c below.
Figure 6.6.c Re-Installing Driver
If you are still experiencing problems, after performing all the above steps, please contact DCL.

7 ADD-ON DEVICES (OPTIONAL)
Remote Monitoring System (Optional)

The remote monitoring system consists of an additional
component which can be tied into the DCL Exhaust
Monitor/Logger system. The system works with the use of
a SIM card. Data is transferred through the cellular
network to a PC, where it can be accessed remotely for
assessment. A monthly plan and additional hardware are
required. For further details regarding this system, please
contact DCL.
CAN Bus System (Optional)

The CAN Bus system consists of an additional component
which can be tied into the DCL Exhaust Monitor/Logger
system. The system provides the necessary connections
allowing for the output or data logging of J1939 signals. For
additional information regarding this system, please contact
DCL.

8 DCL EXHAUST MONITOR/LOGGER ELECTRICAL DIAGRAM

APPENDIX A
Technical Information and Specifications

Control Box (ECU)
Temperature Ambient temperature: Measuring range:
-20 - 80 °C 50 … 1050 °C
Pressure Measuring range: Tolerance:
0 - 600 mbar 2% of full scale
Overpressure safe up
to: max. 2.0 bar
Power supply: 10 - 30 V DC
Current rating: 150–170 mA (in operation);
1 mA (standby)
Protection type: IP63

Alarm outputs: 2 x 5 A power high-side drivers,
Overload-protected, BTS 436
Inputs: min. 9 V
Oscillation level: 10 g at natural frequency
Dimensions: 95 x 100 x 38 mm
Electrical protection: Reverse polarity, short circuiting and overvoltage.

All electrical components and connections are
encapsulated in synthetic resin
PanelBox Off Road (Display)
Protection type IP67 (round shaped instrument)
Dimensions 85 mm , T = 44 mm
Interface : Deutsch Plug
Voltage supply via the ControlBox
Cable harness Measuring range:
Temperature probe: K type max. 1100 °C
Oil- and water-resistant

APPENDIX B
Table 4.2 – Problem Code Determination

Display Description Action
No LEDs on: Alarm Lamp flashing No communication between  Check connection
control box and display panel between wire harness
and display panel
All problem code LEDs On: Alarm Lamp Control box and display face  Control box may need
flashing software incompatibility to be replaced, contact
DCL
Alarm Code 1 On: Alarm Lamp flashing Additive dosing error (if used)  Problem with fuel
(Pressure 8 off) additive system.
 Contact
DCL
Alarm Code 1 On: Alarm Lamp flashing Upper pressure limit  Manually reset the
& Pressure indicator 8 flashing monitor by moving
your finger over the
alarm reset sensor DPF
may need to be cleaned.
Contact DCL

Alarm Code 2 On: Alarm Lamp flashing Lower pressure limit  Check all pressure
& Pressure indicator 1 flashing connections for leaks
 Ensure condensate trap
is closed
 Increase throttle/load
Alarm Code 3 On: Alarm Lamp flashing No rpm signal from generator  If this error is generated
(if used) while engine is running,
check control box
connections.
Alarm Code 4 On: Alarm Lamp flashing Control box cannot  Ensure GSM/GPRS
(Pressure 1 off) communicate with network module is connected
 Check for incorrectly
wired cables, or loose
connectors
Alarm Code 4 On: Alarm Lamp flashing No change of pressure reading  Check all pressure
& Pressure indicator 1 flashing in last 10 minutes connections

Alarm Code 4-8: Alarm Lamp flashing Glass cover needs to be  Clean glass on display
cleaned panel
Alarm Code 5 On: Alarm Lamp flashing No change in temperature  Check thermocouple
& Temp. 1 indicator flashing reading in last 10 minutes connections
Alarm Code 5 On: Alarm Lamp flashing Control box cannot  Contact DCL
(Temp. 1 off) communicate with remote
monitoring system
Alarm Code 6 On: Alarm Lamp flashing Damaged thermocouple  Replace thermocouple
& Temp. 1 indicator flashing

Alarm Code 7 On: Alarm Lamp flashing Date and time not set (data is  Ensure module is
not being recorded) connected
 See section 6.6
Alarm Code 8 On: & Alarm Lamp Low additive fuel tank level  Refill fuel additives
flashing
If encountering a problem code not mentioned above, please call DCL*
*Please call DCL Technical Support at 1-800-872-1968

More detailed information and instructions on actions to take when experiencing any of the above mentioned alarm
codes, may be available in the MINE-X SOOTFILTER® Installation Operation and Maintenance Manual.


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INSTALLATION, OPERATION & MAINTENANCE

P.O. Box 90, Concord, Ontario, Canada L4K 1B2

Toll Free: 1-800-872-1968 Fax: 905-660-6435 Email: info@dcl-inc.com

DCL EXHAUST MONITOR/LOGGER

1 GENERAL SYSTEM DESCRIPTION ....................................................................................................................................... 1

1.1 Logger Basics........................................................................................................................................................................... 1

3.1 Mounting the Control Box ..................................................................................................................................................... 6

4.1 Pressure Monitor Display....................................................................................................................................................... 9

6 DOWNLOAD KIT & SOFTWARE (OPTIONAL).................................................................................................................13

6.1 Software Installation Instructions ........................................................................................................................................14

8 DCL EXHAUST MONITOR/LOGGER ELECTRICAL DIAGRAM ....................................................................................23

1 GENERAL SYSTEM DESCRIPTION

1.1 Logger Basics

The Exhaust Monitor/Logger has two separate memories:

1.2.a Memory for Measured Values

1.2.b Memory for the Alarm Function

DCL EXHAUST MONITOR/LOGGER 1/28

1.4 Special Programs

DCL EXHAUST MONITOR/LOGGER 2/28

Table 2.1 – Components List

DCL EXHAUST MONITOR/LOGGER 3/28

FUSE KIT (X0800-0036-08)

DCL EXHAUST MONITOR/LOGGER 4/28

Must be mounted vertically in a location that will allow

CABLE HARNESS (X0800-0036-02)

DISPLAY PANEL (X0800-0036-04)

DCL EXHAUST MONITOR/LOGGER 5/28

3.1 Mounting the Control Box

Disconnect battery before proceeding with sections 3.1- 3.5

DCL EXHAUST MONITOR/LOGGER 6/28

Ensure to ground while welding.

3.4 Mounting the Display

3.5 Making the Cable Harness Connections

1) Disconnect the battery (should already be disconnected from section 3.1).

DCL EXHAUST MONITOR/LOGGER 7/28

Twist to close Twist to open

Fig. 3.1 Acceptable Set-Up Set Up

DCL EXHAUST MONITOR/LOGGER 8/28

4.1 Pressure Monitor Display

Temperature Indicator LED Bar

Pressure Indicator LED Bar

Problem Code LED Bar

Figure 4.1 – DCL Exhaust Monitor/Logger Display Panel

Table 4.1 – Display Panel Features

DCL EXHAUST MONITOR/LOGGER 9/28

What to Look For: On the Display Monitor, problem code 1 LED

Alarm Description: Pressure inside the filter has increased to a level

DCL EXHAUST MONITOR/LOGGER 10/28

Alarm Description: If you experience Alarm Code 7 this means the

DCL EXHAUST MONITOR/LOGGER 11/28

Table 5.1 – Regular Maintenance Schedule

DCL EXHAUST MONITOR/LOGGER 12/28

6 DOWNLOAD KIT & SOFTWARE (OPTIONAL)

Table 6.1 Download Kit Parts List

CD for Software Installation

Converter: Ethernet -Female Deutsch

Network Cable (X0800-0034-02)

USB Signal Converter (X0800-0034-01)

USB Extension (X0800-0034-03)

DCL EXHAUST MONITOR/LOGGER 13/28

1) Do not connect the signal converter to your PC/laptop at this stage!

Figure 6.1 Setting Language to English

DCL EXHAUST MONITOR/LOGGER 14/28