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KOROSI SPECINDO
Corrosion Monitoring System Eng. Doc. No.: KS-MNL-10
Users Manual
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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
5 Firmware 14
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1. Safety Instruction
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.
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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.
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.
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 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.
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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
Setting up the reading at long interval or short interval can affect the battery
lifespan.
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.
Yoke mounting can be order separately, which customer able to install DCI
Box directly in the field pipe mounting both horizontal or vertical position.
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
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.
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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:
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:
> <
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:
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:
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:
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.
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WRITE READ INTERVAL
HHMM
> 2400 <
(1) SEND (2) ABORT
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:
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.
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:
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.
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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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