Corrosion Monitoring System KS-RND-MNL-21

Instruction & Operation Manual

KS - DCL
Intrinsic Safety Display of Corrosion Logger

Revision Date Prepared Approved Description

1 1/20/2020 JS YS Issued for Approval
 Table of Contents

1. SAFETY INSTRUCTION ......................................................................................................................... 3

2. Introduction ....................................................................................................................................... 4
2.1 General Overview ......................................................................................................................... 4
2.2 Equipment List .............................................................................................................................. 4
2.3 Technical Specification .................................................................................................................. 5
3. Instrument Installation ....................................................................................................................... 5
3.1 Preparation .................................................................................................................................. 5
3.2 Power supply ................................................................................................................................ 6
3.3 Instrument Connection ................................................................................................................. 6
4. Setup and Operation .......................................................................................................................... 7
4.1 Initial Display ................................................................................................................................ 7
4.2 Parameter setting ......................................................................................................................... 7
4.3 Taking data from KS-DCL ............................................................................................................. 10
4.4 Calibration.................................................................................................................................. 10
4.5 Maintenance .............................................................................................................................. 11
5. Firmware ......................................................................................................................................... 11
6. Special Condition for Safe Use (X) ..................................................................................................... 11
Appendix 1. Parameter value for Probe type ......................................................................................... 12
Appendix 2. Interval Time conversion .................................................................................................. 13
Appendix 3. Modbus RTU Format ........................................................................................................ 13
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 that 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 could result in death

DANGER
or serious bodily injury if the safety instruction is not observed

"WARNING" indicates the existence of hazard that could result in bodily

WARNING
injury if the safety instruction is not observed

"CAUTION" indicates the existence of a hazard that could result in

CAUTION
property damage if the safety instruction is not observed

"NOTICE" contains general information that relates to the safe

NOTICE
operation of the equipment
2. Introduction
2.1 General Overview
Model KS-DCL is specially made for display of KS Corrosion transmitter, and intrinsically safe (IS)
instrument. KS-DCL has input of 4-20mA signal and also with dual capability for RS-485 converter to
connected to PLC, DCS or PC. It has also storage of 4000 data, so the data can be retrieved by USB Storage
to be analyzed by KMS software (Korosi Monitoring System) to get corrosion rate.

Fig1. KS-DCL figure

2.2 Equipment List

• KS-DCL
• Power barrier (MTL-7728+), Signal Barrier (MTL-5541), Power Supply (TDK-DPP-15-24) - optional

KS Transmitter that can be use this equipment:

• DCI-Tx series (ER/LPR Corrosion Transmitter)

• KS-UT100-Tx series (UT thickness Corrosion transmitter)

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 indo@korosispecindo.com

Website : http://www.korosispecindo.com

KOROSI SPECINDO

Jl. Pangeran Jayakarta No.76, Jakarta 10730 Indonesia

Phone: 62-21 6267576 (Hunting) Fax: 62-21 6289919

2.3 Technical Specification

Model:
KS-DCL : Intrinsically Safe Corrosion Data logger

Physical Data:
• Instrument Weight : 0.40 kgs
• Instrument dimension : 96 mm x 48 mm x 80 mm
• Ambient Temperature : -200 C ~ +600 C

• Intrinsic Safety Certification : II 1 / 2 G Ex ia IIC T4 Ga/Gb

• Enclosure Protection : IP65

Feature:
• Input Signal : 4-20mA line (2 wire / 3 wire)
• Display type : 7 segment display, 4 digits
• Additional Feature : Modbus RS-485 converter (optional Modbus output)
Retrievable up to 4000 data with KS format via USB
IS (Intrinsic Safety) certified
Easy operation
Electrical Data
• Power Supply : 12 – 26 VDC input
• Power : app. 40mA normal operation, 60mA during USB copy

3. Instrument Installation
DCL is used for display from analog 4-20mA transmitter data to represent in actual value (mils / mpy unit
for ER transmitter or mm unit for UT thickness gauging), and can be installed in both Hazardous area (but
covered from water drops) and also in safety area.

3.1 Preparation
• Safety Procedure always ask for a person who will be in charged in the field, specifically an
Instrument, or Electrical Engineer who will take responsibility in the field during Installation of KS-
DCL.
• Follow wiring diagram and install it correctly before connecting to power supply
• KS-DCL must be protected for water drops, rain or potential damp environment
• Always Test all of your Equipment before you attempt to installed this in the field. Prepare any
tools/instrument such as, multimeter, 4-20mA/HART tester, etc.
• 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 EN60079-10, EN60079-14, EN60079-
17 latest standard.
3.2 Power supply
Adjust power supply output to its rating voltage before connect to KS-DCL.

3.3 Instrument Connection

Fig 2. KS-DCL backside terminal connection

KS-DCL can be installed in Hazardous area and also Safety area.

Fig 3. KS-DCL wiring in Hazardous area

Fig 4. KS-DCL wiring in Safety area

4. Setup and Operation
Soon after installed the power source (pin 5 and 6) or as Fig. 3 or Fig. 4, KS-DCL is ready to operate. It has
default factory setting, so for customized operation it must be set as customer’s specification.

Setting should be done in safety area, as it needs to open the front cover and access to the operation
button of KS-DCL.

This procedure only valid for firmware version: 1.2

OK

KS-DCL 4-20mA Cancel

down

7 segment
Up
display

USB
port

Fig 5. KS-DCL button/port

4.1 Initial Display

Once it power ON, the display will be all lit up for 2 sec, and start count-down from 9 to 0 and will go to
Main screen

The display of main screen will be between 0.000 to 25.00 based on the actual 4-20mA actual reading (if
already connected to 4-20mA loop)

4.2 Parameter setting

To enter parameter setting, press OK button for 3 sec, so the display will show for “Tag”, it will start for
setting Tag no:

a. Parameter 001 (Tag Number)

(button OK Pressed) (value between 1-9999)

(Button Back Pressed)

b. Parameter 002 (Probe Type)

(button OK Pressed) (value between 1-…)

(Button Back Pressed)
For probe type numbering, please see Appendix 1.

c. Parameter 003 (Read interval)

(button OK Pressed) (value between 1-1440min)

(Button Back Pressed)
This is in minute unit, for conversion to hour unit, please see Appendix 2.
d. Parameter 004 (Modbus Slave ID) for RS-485 converter

(button OK Pressed) (value between 1-255)

(Button Back Pressed)

e. Parameter 005 (serial Baud rate)

(button OK Pressed)
(Button Back Pressed)
4800

9600

19200

38400

57600

115200

f. Parameter 006 (Zero Input Adjust)

(button OK Pressed) (value between 0-9999)

(Button Back Pressed)

g. Parameter 007 (Span Input Adjust)

(button OK Pressed) (value between 0-9999)

(Button Back Pressed)

h. Parameter 008 (hour RTC Set)

(button OK Pressed) (value between 0-23)

(Button Back Pressed)

i. Parameter 009 (minute RTC Set)

(button OK Pressed) (value between 0-59)

(Button Back Pressed)

j. Parameter 010 (date RTC Set)

(button OK Pressed) (value between 1-31)

(Button Back Pressed)
k. Parameter 011 (Month RTC Set)

(button OK Pressed) (value between 1-12)

(Button Back Pressed)

l. Parameter 012 (Year RTC Set)

(button OK Pressed) (value between 1- xxxx)

(Button Back Pressed)

m. Parameter 013 (Display Brightness Level)

(button OK Pressed)
(Button Back Pressed)
high

Medium

Low

n. Parameter 014 (Show actual Memory)

Value indicate the actual memory pointer at eeprom, dot at the end of digits represent the memory
is overflow and the data will be stored by FIFO method.

(button OK Pressed) (value between 1- 4000)

(Button Back Pressed)
o. Parameter 015 (Factory Reset)
reset all configuretion data ( interval, probe type, tag number,zero span, calibration) to default
press OK after YES- displayed will affect the change.

(button OK Pressed) (success)

(Button Back Pressed)

p. Parameter 016 (Write protect Calibration Zero/Span)

(button OK Pressed)
(Button Back Pressed)
Protected from changes,

Unprotected from changes

 q. Parameter 017 (Clear All Logging Data on Memory)
erase all Log data and set the index/pointer of memory to 1
press OK after “rst data to 0” displayed will affect the change.

button OK Pressed)
(success)
(Button Back Pressed)

To save parameter setting, press OK after change the value, and device will display if

successfully saved to EEPROM memory, and will display if error occurred and need to
repeat the setting procedure again.

4.3 Taking data from KS-DCL

To collect data from KS-DCL, it’s necessary to provide USB flash drive (minimum USB 2.0, 512MB minimum
space)

When USB Flash drive is plugged in to KS-DCL USB slot, the display will change to

Press OK for downloading from internal memory to USB flash drive, the device will display the remaining

data count to be writen for ex. .

KS-DCL will count down the display until zero/ done. and will display “DONE” if data successfully
downloaded to USB Flash drive, otherwise it will show display “E0XX” if error occurred.

XX : exception code

WARNING : USB Flash drive downloading only can be performed in Non-hazardous area, and shall not be
done if KS-DCL is connected in Hazardous area as Fig. 3

4.4 Calibration
By defaults KS-DCL has been calibrated from the factory. make sure unclock the protection
from parameter menu before doing this calibration procedure, if you want to change the
calibration procedure as follows:
- connect KS-DCL to reference meter/current source at Loop+ and Loop- terminal
- set Current source to 4mA (you can use DCI -Tx as current source)
- at main screen/ default screen press & hold CANCEL + DOWN button until displayed “Zero”
- set current source to 20mA
- press & hold CANCEL + UP button until displayed “Span”
- finish, you can verify it by current loop test.
4.5 Maintenance

• Ensure that display of KS-DCL is functioning well

• Clean the enclosure of KS-DCL from dust, and if there is potential damp and wet from
environment, it’s needed to give protection.
• 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 EN60079-10, EN60079-14, EN60079-
17 latest standard.

5. Firmware
KS-DCL 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.

6. Special Condition for Safe Use (X)

• The cleaning of the enclosure of the KS-DCL unit must be done only with damped clothes because of the
danger of the electrostatic charging
• Do not replace the battery pack of the corrosion data logger KS-UT100 in a potentially explosive
atmosphere.
• In operation the local safety requirements, the safety requirements according to described in operating-
and maintenance manual of equipment, the requirements of the relating explosionproof standards as
well as the requirements and instructions of EN 60079-10:2003, EN 60079-14:2003, and EN 60079-
17:2003 standards must be kept
Appendix 1. Parameter value for Probe type

Parameter Probe type

Value
ER Probe
1 FL10
2 FL20
3 FL40
4 TU10
5 TU20
6 TU40
7 TU80
8 TL4
9 TL8
10 WL40
11 WL80
12 SA40
13 SA80
14 SA120
LPR Probe
15 FL 3 ELECTRODES ST
16 PR 3 ELECTRODES ST
17 FL 3 ELECTRODES RD
18 PR 3 ELECTRODES RD
19 FL 2 ELECTRODES ST
20 PR 2 ELECTRODES ST
21 FL 2 ELECTRODES RD
22 PR 2 ELECTRODES RD
UT PROBE
23 UT1
24 UT4
25 UT8
26 UT16
27 UT32
N-CORR
28 NC-FL-10
29 NC-FL-20
30 NC-TU-10
31 NC-TU-40
32 NC-TU-80
Appendix 2. Interval Time conversion

Input Parameter interval Actual Interval time

1 1 min
5 5 min
60 1 hour
120 2 hours
240 4 hours
360 6 hours
480 8 hours
720 12 hours
1440 24 hours (daily)

Appendix 3. Modbus RTU Format

Standard Modbus RTU Format, 8 bit, no parity, 1 stop bit

Holding Register List (Function Code : 03)

Address Data Property Data Type Desc
000 Unique ID Read/Write Int16 Device Type( DCL = 0xA55A)
001 Tag Number Read/Write Int16 Tag number(0-9999) with prefix
“KS_DCL_XXXX”
002 Probe type Read/Write Int16 See Section 3
003 Interval Read/Write Int16 Log interval
004 Slave ID Read/Write Int16 Modbus slave id
005 Baudrate Read/Write Int16 See parameter 005 (section 1g)
006 Zero Read/Write Int16 Zero value
007 Span Read/Write Int16 Span Value
008 Brightness Read/Write Int16 Backlight control
009 Password Read/Write Char[4] Password for enter configuration
011 Log Data Count Read/Write Int16 Count of data in EEPROM
012 Overflow Read/Write Int16 Reserved
013 Hours Read/Write Int16 RTC Hours
014 Minutes Read/Write Int16 RTC Minutes
015 Seconds Read/Write Int16 RTC Seconds
016 Date Read/Write Int16 RTC Date
017 Month Read/Write Int16 RTC Month
018 Year Read/Write Int16 RTC Year

Measurement Data (Function Code: 04)

000 Module Read Int16 Read Module Ambient

Temperature Temperature
001 4-20 mA Value Read Int16 Read 4-20 ma value from input